2016 OA Motor Catalog PDF

Orbital ATK, Inc.
Orbital ATK, Inc.

Missile Products Propulsion Systems
55 Thiokol Road 5000 South 8400 West
Elkton, MD 21921 Magna, UT 84044
Tel (410) 392-1000 Tel (801) 250-5911
Fax (410) 392-1205
Dear Customer:
Orbital ATK would like to take this opportunity to provide you with the latest version of our Propulsion
Products Catalog to help you address your future propulsion requirements. This catalog describes
flight-proven motors and development motors in our product line. These products provide a
wide range of proven designs, existing manufacturing processes, and tooling which enable paths
to lower risk and lower cost solutions to your requirements. Generally, flight-proven current
production products can be delivered the soonest for the least risk and lowest non-recurring cost,
providing some advantages over new designs.
If current production motors contained in this catalog do not address specific needs, we have the
capability to modify designs to meet application motor performance requirements. The practicality
of tailoring motor performance has been demonstrated many times in derivatives of earlier design
configurations (many examples exist in the STAR™, Orion, and CASTOR® series, for instance).
Orbital ATK would be happy to work with you to evaluate and optimize potential solutions to your
requirements, so don’t hesitate to contact us.
Orbital ATK continues to invest in the development of new products and capabilities. Ongoing
activities include new stage propulsion as well as extensive work with controllable solid-propulsion
systems, which use proportional valves to control performance, and liquid and electric propulsion
for small spacecraft.
Orbital ATK is committed to being the propulsion provider of choice to multiple customers and
markets. This demonstrated commitment has resulted in decades of reliable launch success.
We look forward to and encourage future collaborations and partnerships with commercial
and government customers that satisfy and service a broad range of propulsion needs and
opportunities.
Orbital ATK Propulsion Products Catalog
Table of Contents
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LARGE MOTOR SUMMARY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ORION MOTOR SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ORION 50S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ORION 50ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ORION 50SG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ORION 50S XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ORION 50S XLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ORION 50S XLG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ORION 50 (50T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ORION 50 XL (50 XLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ORION 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ORION 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CASTOR MOTOR SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CASTOR IVA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CASTOR IVA-XL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CASTOR IVB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CASTOR 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CASTOR 30B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
CASTOR 30XL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CASTOR 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CASTOR 120XL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LARGE CLASS STAGE (LCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LCS I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LCS III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GEM MOTOR SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
GEM 40 (GROUND IGNITED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GEM 40 (AIR IGNITED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GEM 40 VN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
GEM 46 (FIXED, GROUND-IGNITED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GEM 46 (VECTORABLE, GROUND-IGNITED) . . . . . . . . . . . . . . . . . . . . . . . . 42
GEM 46 (FIXED, AIR-IGNITED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GEM 60 (VECTORABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
GEM 60 (FIXED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
GEM 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GEM 63XL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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Approved for Public Release OSR No. 16-S-1432; Dated 05 April 2016
SOLID ROCKET MOTOR UPGRADE (SRMU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SRMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REUSABLE SOLID ROCKET MOTOR (RSRM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
RSRM DERIVATIVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1-segment RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.5-segment RSRM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2-segment RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.5-segment RSRM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3-segment RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4-segment RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5-segment RSRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
STAR MOTOR SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TM
STAR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
STAR 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
STAR 4G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
STAR 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
STAR 5C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
STAR 5CB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
STAR 5D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
STAR 5F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
STAR 6B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
STAR 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
STAR 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
STAR 12GV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
STAR 13B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
STAR 15G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STAR 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
STAR 17A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
STAR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
STAR 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
STAR 24C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
STAR 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
STAR 26B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
STAR 26C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
STAR 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
STAR 27H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
STAR 30 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
STAR 30BP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
STAR 30C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
STAR 30C/BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
STAR 30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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STAR 31 and 37 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

STAR 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
STAR 37FM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
STAR 37FMV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
STAR 37XFP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
STAR 37GV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
STAR 48 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
STAR 48A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
STAR 48A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
STAR 48B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
STAR 48B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
STAR 48BV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
STAR 63 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
STAR 63D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
STAR 63F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
STAR 75 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
STAR 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
STAR 92 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
STAR 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
STAR STAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ELECTROMECHANICAL THRUST VECTOR ACTUATION SYSTEM. . . . . . . . . . . . . . . . 119
ORION LAUNCH ABORT SYSTEM (LAS) ATTITUDE CONTROL MOTOR (ACM). . . . . . 121
ORION LAS ACM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ADVANCED SOLID AXIAL STAGE (ASAS™) MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . 123
ASASTM 13-30V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ASAS 21-85V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
ASAS 21-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
ASAS 21-120V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
ORIOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ASAS 28-185/185V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
ASAS 32-58V (RAVEN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
LAUNCH STRUCTURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
ATLAS V STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
DELTA IV STRUCTURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
GEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ORION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
PEGASUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
ORDNANCE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
MODEL 2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
MODEL 2134B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
SCB INITIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ESA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
EOSA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

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ACRONYM LIST
ACS Attitude control system — A thruster system used to maintain spacecraft/
missile positioning and orientation. Also referred to as a reaction control
system (RCS) in some applications
AKM Apogee kick motor — A motor used to circularize the orbit of a spacecraft,
often to geosynchronous earth orbit (GEO)
ASAS Advanced Solid Axial Stage — ASAS is used as a designation for a family
of enhanced performance motors that generally incorporates common
technologies such as high-strength graphite composite cases, high
performance propellants, advanced ordnance, and/or thrust vector control
nozzles with electromechanical actuation. These motors are identified by
primary diameter, case length, and TVC content. For example, ASAS 21-
120V is a 21-inch-diameter motor with a 120-inch case and TVC nozzle
BIT Built-in test — A feature of electronic devices that allows their operability to
be confirmed via a signal provided in response to a test command or query
CSC Conical shaped charge — An ordnance product typically used as part of

upper stage destruct systems to satisfy range safety requirements
CTPB Carboxyl-terminated polybutadiene — A type of polymer used as a

propellant binder
EOSA Electro-optical safe and arm — A class of safe-and-arm device based on

isolation of the unit and primary initiation functions using laser systems
and fiber optics to reduce weight and eliminate sensitivity to electrostatic
energy that results from the use of long wiring runs for ordnance systems
typically used in launch vehicles
EPDM Ethylene propylene diene monomer — A class of elastomeric rubber

insulation materials typically used to insulate motor cases
ESA Electronic safe and arm — A class of safe-and-arm device based on the
use of semiconductor bridge initiator technology. ESA designs provide
capabilities for reporting health status of the ordnance system and
incorporating specific safety and command and control protocols
ETA Explosive transfer assembly — ETAs are used as part of a space motor
ignition train, generally to transfer the initiation signal from a safe-and-
arm device to another ordnance component such as a through-bulkhead
initiator (TBI). These may be further identified as an FETA = flexible ETA,
or RETA = rigid ETA
ETR Eastern Test Range
GBI Ground-based interceptor
GEM Graphite epoxy motor — Orbital ATK developed GEM designs for the
Delta II launch vehicle. Designed to take advantage of proven, off-the-
v
shelf technologies, the GEM system provides increased performance and

heavier lift capability
GEO Geosynchronous earth orbit — 22,600 miles out from the earth is an orbital
location where satellites remain over a fixed point on the earth
GMD Ground-based Midcourse Defense
GPS Global positioning system — A satellite constellation providing precise

navigation and location data for military and commercial users
GSE Ground support equipment — Equipment used to support motor integration

with the spacecraft and/or launch vehicle and to provide associated final
motor checks
HEW Head end web — A type of grain design in which the propellant completely
covers and is generally bonded to the motor head end
HTPB Hydroxyl terminated polybutadiene — A type of polymer used as a

propellant binder
IMP Interplanetary monitoring platform
IRBM Immediate-range ballistic missile
JPL Jet Propulsion Laboratory, Pasadena, CA
LCS Large class stage – A high-performance, high-reliability booster being

developed by Orbital ATK with the support of the U.S. Air Force
LEO Low earth orbit — A position reached by the Space Shuttle and many
launch systems prior to orbital adjustments that are typically made using
perigee kick motor (PKM) and apogee kick motor (AKM) propulsion
MDA Missile Defense Agency
MER Mars Exploration Rover — Designation for the 2003 to 2004 NASA missions
to Mars that landed the Spirit and Opportunity rovers
NSI NASA standard initiator
PBAN Polybutadiene acrylic acid acrylonitrile polymer — A binder formulation

widely used on large rocket boosters such as the Titan III and Space
Shuttle
PKM Perigee kick motor — A motor typically used to raise a satellite into elliptical
orbit
RAD Rocket-assisted deceleration — Designation for motors used to decelerate

payloads such as the Mars RAD motors
vi
RAVEN RApid VEctoring Nozzle
RCS Reaction control system
RPM Revolutions per minute — Used to designate spin rates used to stabilize
spacecraft. Note that the cited spin rates are the highest levels to which the
design was tested or analyzed, not necessarily its maximum spin capability
RSRM Reusable solid rocket motor — Designation used for the Space Shuttle
boosters
S&A Safe and arm — Used to designate an electronic or electromechanical

device that inhibits ordnance functions to provide enhanced safety
SCB Semiconductor bridge — The SCB chip is used in a line of initiators that
provides fast and repeatable function times using low initiation energy
SLS Space Launch System
SRM Solid rocket motor
SRMU Solid rocket motor upgrade — Originally developed for the U.S. Air Force
and Lockheed Martin to increase the launch capability of the Titan IVB
Space Launch Vehicle (retired)
SSB Solid strap-on booster
STS Space Transportation System — The Space Shuttle
TBI Through bulkhead initiator — Part of a space motor ignition train
TLI Trans-Lunar Injection — Designation for a motor system used to inject a

satellite into a lunar orbit. This specific designation applies to the STAR
37FM-based TLI stage used for the Lunar Prospector spacecraft
TCR Orbital ATK line of resins and pre-impregnated composite materials

available in combination with a variety of fibers for industrial, commercial,
and aerospace applications
TIRS Transverse impulse rocket system — Designation for motors used to

stabilize the lander during descent as part of the Mars Exploration Rover
mission
TVA Thrust vector actuation — Refers to the system used to actuate a TVC
nozzle
TVC Thrust vector control — Refers to a type of movable nozzle
UWARS Universal water activated release system — A program that uses a qualified
SCB initiator produced by Elkton
WTR Western Test Range
vii
viii
INTRODUCTION
Orbital ATK space propulsion and ordnance products outlined in this catalog reflect more
than 50 years of experience in providing high-performance and reliable propulsion for the
aerospace industry. This catalog presents technical information on numerous product lines
within the Orbital ATK Space Propulsion Product portfolio: Orion, CASTOR®, CASTOR
120®, LCS (large class stage), GEM (graphite epoxy motor), SRMU (solid rocket motor
upgrade), the Space Shuttle RSRM (reusable solid rocket motor) and its derivative motors,
the STAR™ series of space motors and integrated upper stages, ASAS™ (advanced solid
axial stage), ordnance products, and space launch structures.
RSRM Boosters GEM and STAR Propulsion CASTOR and Orion

Lift the Space Shuttle Power Delta II Motors Boost Taurus
Solid rocket motor technology provides excellent reliability, tailorable ballistic performance,
and low costs for many space, upper-stage, and missile defense applications. Introduction
of high-strength composite materials has further enhanced performance for many classes
of motors. In addition, Orbital ATK motors with thrust vector control nozzles and attitude
control systems provide significant upgrades in solid propulsion system capabilities.
STAR 48 Motor and Magellan Lunar Prospector LCS I Static Test

Satellite Begin Journey to (STAR 37 Integrated
Venus Stage)
STAR™ and ASAS™ are trademarks of Orbital ATK, Inc. CASTOR® and CASTOR 120® are registered
trademarks of Orbital ATK, Inc.
Copyright © 2016 by Orbital ATK, Inc. All rights reserved.

1
Sometimes existing designs must be modified, stretched, offloaded, or scaled up to achieve

performance goals and/or to accommodate structural interfaces established for specific
missions or applications. Orbital ATK routinely modifies our products to meet evolving
customer needs through detailed design, analysis, and testing of new propulsion systems
that maintain the heritage of prior, flight-proven designs when it saves time and cost.
Rapid Vectoring Nozzle (RAVEN) ASAS 21-120 Motor Test

Demonstration Motor
Our ordnance products have also established excellent flight reliability records in both motor
ignition and destruct system applications. Current electronic safe-and-arm technology can
be applied by Orbital ATK to reduce ordnance weight and cost and to precisely control
ordnance events for your propulsion systems.
We have also included an overview of Orbital ATK’s integrated stage capabilities. Orbital
ATK has a broad range of capabilities, including simple stage hardware and stage/vehicle
integration support, to more complex three-axis stabilized, inertially-guided vehicle designs.
Orbital ATK now offers fully autonomous single or multiple stage stacks and all of the
required avionics hardware, flight software, and mission design and management services.
2
In addition to hardware, Orbital ATK routinely provides a variety of support services,

including engineering design trades, launch and integration support, field handling training,
aging and surveillance, demilitarization, testing, and analysis. These services support
mission assurance goals leading to successful flight. We also routinely provide shipping
containers and ground support equipment for use with the motors. To accommodate new
environments or structural interfaces, we can define and support delta-qualification of
components and/or complete motor assemblies. Orbital ATK can also design skirts and
interstages and provide heaters, thermal blankets, and flight termination ordnance to adapt
our products to your needs.
Shipping Container Lunar Prospector Size

With Lifting Beam Tooling
for Stage/Motor Handling
This catalog contains data sheets that summarize the principal design and performance
characteristics of each existing propulsion product. The information provided in the data
sheets will permit initial evaluation of our current products in reference to your mission
requirements. We encourage you to involve us in these evaluations and welcome the
opportunity to provide optimal solutions for your mission needs.
Inquiries regarding specific product lines should be directed to our business development
representatives as listed below. In addition to the products noted in this catalog, Orbital ATK can
provide reliable space structures, aerospace tanks, and hypersonic propulsion technology.
For information about these and other Orbital ATK products, please visit our website at
www.Orbital ATK.com.
Products Contact No. Contact E-mail Address

STAR, ASAS, and CASTOR I and II Phone: (410) 392-1430 starmotors@Orbital ATK.com
Motors; STAR™ Stages; Ordnance Fax: (410) 392-1205
Orion, CASTOR, LCS, GEM, SRMU, and Phone: (801) 251-5373 commercialmotors@Orbital
RSRM Motors/derivatives Fax: (801) 251-5548 ATK.com
Space Structures Phone: (801) 775-1962 Larry.Mortensen@Orbital ATK.
Fax: (801) 775-1207 com
Tanks Phone: (323) 722-0222 psi.tank@Orbital ATK.com
Fax: (323) 721-6002
Hypersonic Propulsion Technology Phone: (631) 737-6100 GASL.Marketing@Orbital ATK.
Fax: (631) 737-6121 com
3
4
LARGE MOTOR SUMMARY

INFORMATION
ORION, CASTOR, LCS, GEM, AND RSRM
MOTOR SERIES CAPABILITIES
Orbital ATK’s large motor series (Orion, CASTOR, LCS, GEM, and RSRM families) span
a significant range of size and boost capability, with motors ranging from approximately
2,000 pounds up to 1.6 million pounds. The figure on the following page provides a graphic
comparison of the relative sizes of the principal motors in these series.
Tabular summaries of motor dimensions, weights, and performance data across these
motor series are provided in Table 1, and a summary of test and flight experience is
provided in Table 2. (NOTE: Similar summary data is provided under the STAR motor
section for the STAR motor series.)
5
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
RSRMV
RSRM
SRMU
GEM 60
GEM 46
ORION 50S XL
GEM 40
ORION 50ST
LCS I
ORION 32
ORION 50XL
CASTOR 120
ORION 50
CASTOR 30
ORION 38
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
Inches
Orbital ATK Motor Comparision
6
Table 1. Large Motor Summary
Propel-
Overall Total
Diameter lant Mass Total Impulse Burn Time
Motor Nozzle Length Weight Status
(inches) Weight Fraction (lbf-sec) (sec)
(inches) (lbm)
(lbm)
Orion Motor Family
Orion 32 Vectorable 32 121 4,280 4,721 0.91 1,186,000 41.0 Component-qualified
Orion 38 Vectorable 38 52.6 1,698 1,924 0.88 491,140 66.8 Flight-proven
Orion 50 Vectorable 50.2 103.2 6,669 7,395 0.90 1,949,000 75.1 Flight-proven
Orion 50 XL Vectorable 50.2 120.9 8,631 9,494 0.91 2,521,900 71.0 Flight-proven
Orion 50S Fixed 50.2 350.1 26,801 29,529 0.91 7,873,000 74.9 Flight-proven
Orion 50ST Vectorable 50.2 335.4 26,801 29,103 0.92 7,676,500 74.2 Flight-proven
Orion 50S XL Fixed 50.2 404.3 33,145 36,153 0.92 9,744,300 69.7 Flight-proven
Orion 50S XLT Vectorable 50.2 390.8 33,145 35,763 0.93 9,472,400 69.0 Flight-proven
Orion 50S XLG Vectorable 50.2 372.4 33,145 35,525 0.93 9,061,400 69.0 Flight-proven
CASTOR Motor Family
CASTOR IVA Fixed 40.1 363.4 22,286 25,737 0.87 5,967,840 55.2 Flight-proven
CASTOR IVA-XL Fixed 40.1 457.0 28,906 33,031 0.88 8,140,170 58.0 Flight-proven
CASTOR IVB Vectorable 40.1 353.7 21,990 25,441 0.86 5,880,600 63.6 Flight-proven
CASTOR 30 Vectorable 92 144.2 28,098 30,570 0.92 8,239,110 149.8 Flight-proven
CASTOR 30B Vectorable 92 169.7 28,405 30,800 0.92 8,539,320 126.7 Flight-proven
CASTOR 30XL Vectorable 92 235.8 54,949 58,217 0.94 16,174,800 155.0 Flight-proven
CASTOR 120 Vectorable 92 355 107,914 116,993 0.92 30,000,000 79.4 Flight-proven
CASTOR 120XL Vectorable 92.1 378.3 114,194 123,383 0.93 31,872,000 83.5 Qualified
*Large Class Stage (LCS)
*LCS I Vectorable 92.1 378.3 114,194 123,665 0.92 31,774,000 77.9 Qualified
*LCS III Vectorable 92.1 164.5 28,278 31,307 0.91 8,483,300 133.0 Qualified at simulated altitude
Graphite Epoxy Motor (GEM) Family
GEM-40 Fixed 40.4 449.1 25,940 28,883 0.90 7,351,000 63.3 Flight-proven
(Air- Ignited)
GEM-40 VN Vectorable 40.4 425.1 25,940 28,886 0.90 6,959,000 64.6 Flight-proven
GEM-46 Fixed 45.1 495.8 37,180 41,590 0.89 10,425,000 75.9 Flight-proven
(Ground-
Ignited)
7
Propel-
Overall Total
Diameter lant Mass Total Impulse Burn Time
Motor Nozzle Length Weight Status
(inches) Weight Fraction (lbf-sec) (sec)
(inches) (lbm)
(lbm)
GEM-46 Vectorable 45.1 491.5 37,180 42,196 0.88 10,400,000 76.9 Flight-proven
(Ground-
Ignited)
GEM-46 Fixed (Air- 45.1 508.6 37,180 42,039 0.88 10,803,000 75.9 Flight-proven
Ignited)
GEM-60 Fixed 60 518 65,472 73,156 0.89 17,965,776 90.8 Flight-proven
GEM-60 Vectorable 60 518 65,472 74,185 0.88 17,928,000 90.8 Flight-proven
GEM-63 Fixed 63 789.3 * * * * * In development
GEM-63XL Fixed 63 862.0 * * * * * In development
Solid Rocket Motor Upgrade (SRMU)
SRMU Vectorable 126 1,349 695,427 776,038 0.89 195,476,128 135.7 Flight-proven
Reusable Solid Rocket Motor (RSRM) and Derivatives
RSRM Vectorable 146.1 1,513.5 1,106,059 1,255,334 0.88 297,001,731 122.2 Flight-proven
1-Segment Commercial Vectorable 146.1 499.6 336,231 404,601 0.83 92,978,688 115.8 Design
1.5-Segment Com- Vectorable 146.1 697 476,496 558,993 0.85 132,700,522 117 Design
mercial
2-Segment Commercial Vectorable 146.1 860 619,003 715,659 0.86 170,800,000 114.1 Design
2.5-Segment Com- Vectorable 146.1 1,037 758,990 867,215 0.87 209,304,469 113.2 Design
mercial
3-Segment Commercial Vectorable 146.1 1,156.2 843,286 981,686 0.86 223,000,000 133.7 Design
4-Segment Commercial Vectorable 146.1 1,476.3 1,114,155 1,278,078 0.87 298,000,000 132.8 Design
RSRM V Vectorable 146.1 1,864.7 1,427,807 1,616,123 0.88 381,367,646 131.9 Completing qualification
(5-Segment)
* In development, subject to refinement
8
Table 2. Large Motor Test and Flight History as of 22 September 2016
Number of
Number of Motors
Motor Applications/Uses Static Fire TVC Production Status
Flown
Tests
Orion 32 Technology Demonstration 2 (HCDM, 0 Yes Development
MCRT)
Orion 32-5 Technology Demonstration 1 0 Yes Development
Orion 32-7 Technology Demonstration 1 0 Yes Development
Orion 38 Pegasus/Taurus/Pegasus XL/ Taurus 3 77 Optional Production
XL/Minotaur I/Minotaur IV/GMD OBV
Orion 38HP Technology Demonstration 1 0 Yes Development
Orion 50 Pegasus Std 1 10 Optional Out of Production
Orion 50T Taurus Std 0 6 Optional Out of Production
Orion 50 XL Pegasus XL/Minotaur/OBV 2 59 Optional Production
Orion 50 XLT Taurus XL 0 5 Optional Production
Orion 50S Pegasus Std/Hyper-X 1 13 No Out of Production
Orion 50ST Taurus Std 1 6 Optional Out of Production
Orion 50SG 0 0 Optional Out of Production
Orion 50S XL Pegasus XL 1 32 No Production
Orion 50S XLG GMD OBV/ALV/IRBM Target 5 17 Optional Production
Orion 50S XLT Taurus XL 0 3 Optional Production
CASTOR IVA Delta II/Atlas 2AS 7 313 No Out of Production
CASTOR IVB Maxus/Targets 4 33 Yes Out of Production
CASTOR IVA-XL HII-A 4 34 No Out of Production
CASTOR 30 Antares/Athena Ic/Athena IIc 1 2 Yes Production
CASTOR 30B Antares 0 2 Yes Production
CASTOR 30XL Antares 1 1 Yes Production
CASTOR 120 Athena Ic/Athena IIc/ Taurus/Taurus 2 16 Yes Out of production
XL
CASTOR 120XL 0 0 Yes Production
LCS I Conventional Strike/Family of Motors 1 0 Yes Demonstrated
LCS III Conventional Strike/Family of Motors 1 0 Yes Demonstrated
9
Number of
Number of Motors
Motor Applications/Uses Static Fire TVC Production Status
Flown
Tests
GEM 40 Delta 2 13 990 No Production
GEM 40VN GMD BV+ 3 3 Yes Out of Production
GEM 46 Delta 2 Heavy/Delta 3 3 81 Fixed/TVC Out of Production
GEM 60 Delta 4 14 52 Fixed/TVC Production
SRMU Titan IVB 6 34 Yes Out of Production
RSRM Space Shuttle 28 220 Yes Out of Production
(+5-seg ETM-3)
1-Seg. RSRM 0 0 Yes Concept
1.5-Seg. RSRM 0 0 Yes Concept
2-Seg. RSRM 0 0 Yes Concept
2.5-Seg. RSRM 0 0 Yes Concept
3-Seg. RSRM 0 0 Yes Design
4-Seg. RSRM 0 0 Yes Design
RSRM V Space Launch System (SLS) / for- 5 0 Yes Completing development and qualification
(5-Seg.) merly Ares I First Stage (+Ares I-X, 4-seg)
Reliability/Success Rate: Demonstrated success rate of 99.76% in flight and static tests. One static test faillure and four flight failures in
2,121 tests and flights (two TVC related). Two of the flight failures were subsequently attributed to damage resulting from handling and post-
delivery flight processing.
10
ORION MOTOR SERIES
AFFORDABLE, LOW-RISK FLEXIBLE CAPABILITIES
Orion Series
The Orion family of motors began with three stages originally designed for use in a joint
venture with Orbital Sciences Corp. for the Pegasus® launch vehicle. Modifications to the
original three Orion motors, first for extended length (XL) versions and subsequently for
skirt, nozzle, and other smaller differences, have accommodated additional applications
and enhanced performance capabilities. Vehicle applications successfully flown using
Orion motors include Pegasus®, Taurus®, Pegasus® XL, Minotaur®, Hyper-X, Taurus
Lite and Taurus® XL launch vehicles, and the Ground-based Midcourse Defense (GMD)
ground-based interceptor (GBI). New applications continue to evolve, such as target
vehicle configurations for Missile Defense Agency (MDA).
The multiple configurations and applications currently existing demonstrate that these
flight-proven motors are readily adaptable to a wide range of launch scenarios (e.g.,
ground-start, air-start, silo-launched, etc.) and missions. Orbital ATK has also demonstrated
support for their deployment and use at a wide range of launch sites and field locations,
including multiple non-Continental United States launch sites. Further, it should be noted
that much of the adaptation has been accomplished with only relatively minor changes
(skirt thicknesses and hole patterns, nozzle length, etc.), with little or no changes to the
basic motor.
The current major vehicle applications and variants for Orion motors are shown in the
table below. The motor identification key provides a further explanation for nomenclature
designations in the Orion motor series.
11
Flight-Proven Orion Motor Configurations

Orion Motor
Vehicle Application
First Stage Second Stage Third Stage Fourth Stage
50S 50 38 Pegasus
50S XL 50 XL 38 Pegasus XL
50ST 50T 38 Taurus
50S XL 50 XLT 38 Taurus XL/

Minotaur C
50S XLG 50 XL 38 Taurus Lite
50 XL 38 Minotaur I
38 Minotaur IV
50S Hyper-X
50S XLG 50 XL 38 GMD GBI
50S XLG* 50 XLT IRBM target
* with lengthened nozzle
Motor Identification Key
Example Orion 50 S XL G T
 SRM class
 SRM diameter (in)
 Stretch
• With “S” denotes Stage 1
• Without “S” denotes Stage 2
 XL or Std motor length

• “XL” denotes extra length (otherwise standard length)
 Nozzle configuration
• “G” denotes ground-launched (truncated exit cone)
 Thicker skirt
• “T” denotes thicker skirt (increased structural capacity)
12
ORION 50S
MOTOR DIMENSIONS
Motor diameter, in.................................................50.2
Overall motor length (including nozzle), in.........350.1
Nozzle exit cone diameter, in................................56.0
MOTOR PERFORMANCE (60°F NOMINAL,

VACUUM)
Burn time to 30 psia, sec......................................74.9
Maximum thrust, lbf........................................126,641
AIR-IGNITED, FIXED NOZZLE Effective specific impulse, lbf-sec/lbm…........ 292.25*
The Orion 50S was developed as a low-cost, high-performance Total impulse, lbf-sec................................. 7,873,000*
Burn time average thrust, lbf..........................105,097
first stage for the Pegasus launch vehicle. The 50S configuration,
* Includes 137 lbm of expended inerts
shown above incorporating a saddle attachment, has a fixed nozzle
and is air ignited after a 5-second freefall drop from approximately WEIGHTS, LBM
40,000 ft. The Orion 50S has launched Pegasus satellite missions Total motor........................................................29,529
Propellant ........................................................26,801
into successful orbit, some of which were Pegsat, Microsat, SCD-
Burnout...............................................................2,533
1 (Brazil’s first data collection satellite), Alexis, and Space Test
Experiment Platform (STEP)-2. This motor, with some additional PROPELLANT DESIGNATION
.............. QDL-1, HTPB POLYMER, 19% ALUMINUM
modifications, has also been used as a booster in Hyper-X flights
to support scramjet flight-testing. HAZARDS CLASSIFICATION…................... 1.3
RACEWAY........................................ OPTIONAL
ORDNANCE..................................... OPTIONAL
TVA ...............................................................NO
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage….................................................+30°-100°F
PRODUCTION STATUS
........... FLIGHT PROVEN, INACTIVE PRODUCTION
** Pegasus standard first stage
Approved for Public Release

OSR No. 16-S-1432; 13
Dated 05 April 2016
ORION 50ST
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................74.2
Effective specific impulse, lbf-sec/lbm…........ 284.97*
Total impulse, lbf-sec................................. 7,676,500*
WEIGHTS, LBM
Total motor........................................................29,103
Propellant ........................................................26,801
AIR-IGNITED, VECTORABLE NOZZLE Burnout...............................................................2,165
Another version, Orion 50ST, incorporates a ± 5-degree moveable PROPELLANT DESIGNATION
nozzle for the air-ignited, Taurus Stage 1. This version has flown on .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
all six Taurus missions (both Air Force and commercial versions), HAZARDS CLASSIFICATION…................... 1.3
such as the Multi-Spectral Thermal Imager (MTI), Orbview-4,
Korea Multi-Purpose Satellite (KOMPSAT), etc.
ORDNANCE .................................... OPTIONAL
TVA .................................................. OPTIONAL
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
........... FLIGHT-PROVEN, INACTIVE PRODUCTION
** Taurus standard first stage

OSR No. 16-S-1432; 14
Dated 05 April 2016
ORION 50SG
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................74.2
Maximum thrust, lbf........................................ 117,358
Effective specific impulse, lbf-sec/lbm….......... 273.7*
Burn time average thrust, lbf............................99,268
WEIGHTS, LBM
Total motor........................................................28,865
Propellant ........................................................26,801
GROUND-IGNITED, VECTORABLE NOZZLE
Burnout...............................................................1,930
Another version, Orion 50SG, incorporates a ± 3-degree moveable
nozzle for a ground-ignited Stage 1 configuration. This version is PROPELLANT DESIGNATION
similar to what has flown on the standard Taurus missions, but
with a shorter nozzle. HAZARDS CLASSIFICATION…................... 1.3
TVA .................................................. OPTIONAL
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
................... QUALIFIED, INACTIVE PRODUCTION

OSR No. 16-S-1432; 15
Dated 05 April 2016
ORION 50S XL
MOTOR DIMENSIONS

VACUUM)
Effective specific impulse, lbf-sec/lbm…........ 292.78*
AIR-IGNITED, FIXED NOZZLE
WEIGHTS, LBM
A performance upgrade of the Orion 50S, the Orion 50S XL, is 55.4 Total motor........................................................36,153
inches longer and contains 6,500 lbm more propellant. To date, Propellant ........................................................33,145
this fixed-nozzle XL version has performed successfully on 32 Burnout...............................................................2,837
Pegasus XL launch vehicle missions, such as the Solar Radiation PROPELLANT DESIGNATION
and Climate Experiment (SORCE), Fast Auroral Snapshot (FAST), .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
High Energy Solar Spectroscopic Imager (HESSI), Orbview-3, and HAZARDS CLASSIFICATION…................... 1.3
Transition Region and Coronal Explorer (TRACE).
RACEWAY ....................................... OPTIONAL
TVA ...............................................................NO
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
.......................... FLIGHT-PROVEN, PRODUCTION
**Pegasus XL first stage

OSR No. 16-S-1432; 16
Dated 05 April 2016
ORION 50S XLT
MOTOR DIMENSIONS

VACUUM)
Maximum thrust, lbf….....................................156,823
Effective specific impulse, lbf-sec/lbm............ 284.61*
WEIGHTS, LBM
Total motor........................................................35,763
Propellant ........................................................33,145
AIR-IGNITED, VECTORABLE NOZZLE Burnout...............................................................2,472
Vectorable nozzle configurations of the Orion 50S XL have also PROPELLANT DESIGNATION
been added to support versatility and new applications. One such .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
configuration, Orion 50S XLT, has been used as a second-stage HAZARDS CLASSIFICATION…................... 1.3
motor on the enhanced Taurus XL vehicle, which first launched
in May 2004. This version incorporates a ± 5-degree vectorable
nozzle and thicker skirts. ORDNANCE .................................... OPTIONAL
TVA .................................................. OPTIONAL
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
.............................FLIGHT-PROVEN, PRODUCTION
**Taurus XL first stage

OSR No. 16-S-1432; 17
Dated 05 April 2016
ORION 50S XLG
MOTOR DIMENSIONS

VACUUM)
WEIGHTS, LBM
Total motor........................................................35,525
Propellant ........................................................33,145
GROUND-IGNITED, VECTORABLE NOZZLE Burnout...............................................................2,237
A ground ignited, vectorable nozzle configuration with ± 5-degree
PROPELLANT DESIGNATION
vector capability has also been developed, designated Orion .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
50S XLG. This motor was first flown on the Taurus Lite vehicle,
HAZARDS CLASSIFICATION…................... 1.3
February 2003, as the ground-ignited first stage.
TVA .................................................. OPTIONAL
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
**Taurus Lite and GMD first stage

OSR No. 16-S-1432; 18
Dated 05 April 2016
ORION 50 (50T)
MOTOR DIMENSIONS

VACUUM)
Maximum thrust, lbf….......................................29,554
* Includes 46.4 lbm of expended inerts
WEIGHTS, LBM
Total motor..........................................................7,395
Propellant ..........................................................6,669
AIR-IGNITED, VECTORABLE NOZZLE Burnout..................................................................670
The Orion 50 was developed as a low-cost, high-performance .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
second stage for the Pegasus launch vehicle. It incorporates a
moveable nozzle with ± 5-degree vector capability. The motor was HAZARDS CLASSIFICATION…................... 1.3
designed for upper stage applications but can readily accommodate RACEWAY................................................... YES
lower expansion ratios, such as for ground-launch application,
using a truncated nozzle. The Orion 50 has propelled 10 satellite
missions into successful orbit, including: Pegsat, Microsat, SCD- TVA................................................... OPTIONAL
1 (Brazil’s first data collection satellite), Alexis, and Space Test
Experiment Platform (STEP)-2. A nearly identical version with TEMPERATURE LIMITS
slightly enhanced skirts, the Orion 50T, has also flown successfully Operation..................................................+36°-100°F
on six Taurus launch vehicle flights. STORAGE....................................... +30°-100°F
PRODUCTION STATUS
**Pegasus and Taurus standard second stage

OSR No. 16-S-1432; 19
Dated 05 April 2016
ORION 50 XL (50 XLT)
MOTOR DIMENSIONS

VACUUM)
Maximum thrust, lbf….......................................43,713
Burn time average thrust, lbf............................ 35,511
WEIGHTS, lbm
Total motor..........................................................9,494
AIR-IGNITED, VECTORABLE NOZZLE
Propellant ..........................................................8,631
A flight-proven, extended-length version of the initial Orion 50 is Burnout..................................................................808
also available. The Orion 50 XL is 18 inches longer and contains
almost 2,000 lbm more propellant than the Orion 50. It flew on .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
the 1995 Space Test Experiment Platform (STEP)-3 mission as
the second stage of the Pegasus XL. It has also flown as the
third-stage motor for the Air Force’s Minotaur launch vehicle as RACEWAY................................................... YES
part of the Orbital/Suborbital Program and as the second stage ORDNANCE .................................... OPTIONAL
on the Taurus Lite vehicle. In addition, a nearly identical version
TVA .................................................. OPTIONAL
with heavier skirts, the Orion 50 XLT, launched in May 2004 as a
second-stage motor on the enhanced Taurus XL launch vehicle. TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
**Pegasus XL second stage, Minotaur I third
stage

OSR No. 16-S-1432; 20
Dated 05 April 2016
ORION 38
MOTOR DIMENSIONS
Overall motor length (including nozzle), in...........52.6

VACUUM)
Maximum thrust, lbf….........................................8,303
Total impulse, lbf-sec.................................... 491,140*
Burn time average thrust, lbf..............................7,352
WEIGHTS, lbm
Total motor..........................................................1,924
Propellant ..........................................................1,698
AIR-IGNITED, VECTORABLE NOZZLE Burnout..................................................................206
UPPER-STAGE BOOSTER PROPELLANT DESIGNATION
The Orion 38 was developed as a low-cost, high-performance third .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
stage for the Pegasus launch vehicle and incorporates a ± 5-degree HAZARDS CLASSIFICATION…................... 1.3
vectorable nozzle. It also functions as the standard third-stage motor
RACEWAY.....................................................NO
for other launch vehicles such as the Pegasus XL; Taurus, Taurus
XL, and Taurus Lite launch vehicles; and as the fourth stage of the ORDNANCE .................................... OPTIONAL
Air Force’s Minotaur vehicle. This motor has performed successfully TVA .................................................. OPTIONAL
in more than 75 flights over two decades of use.
TEMPERATURE LIMITS
Operation..................................................+36°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS

OSR No. 16-S-1432; 21
Dated 05 April 2016
ORION 32
MOTOR DIMENSIONS
Motor diameter, in....................................................32
Overall motor length (including nozzle), in............121

VACUUM)
Burn time, sec..........................................................41
Average chamber pressure, psia...........................660
Total impulse, lbf-sec...................................1,186,000
NOZZLE
Housing material..........................................Aluminum
Exit diameter, in....................................................24.9
Expansion ratio, average.........................................23
WEIGHTS, lbm
VECTORABLE NOZZLE IN-LINE BOOSTER
Total loaded........................................................4,721
The Orion 32 is a low-cost, high-performance derivative of an Propellant ..........................................................4,280
existing upper-stage motor. This development motor is 121 inches Burnout..................................................................418
long and nominally designed as a second-stage motor. A longer
version (up to 255 inches) for potential first stage application and .............. QDL-2, HTPB POLYMER, 20% ALUMINUM
a reduced length version (down to 70 inches) are also in design
RACEWAY ....................................... OPTIONAL
evaluation. This motor configuration has not flown; however, all
components, except skirts, are flight-proven. ORDNANCE .................................... OPTIONAL
TVA .................................................. OPTIONAL
TEMPERATURE LIMITS
Operation..................................................+20°-100°F
Storage.....................................................+20°-100°F
PRODUCTION STATUS...................IN DESIGN
Thrust vs Time Profile

35,000
30,000
25,000
Vacuum Thrust (lbf)
20,000
15,000
10,000
5,000
0
0 10 20 30 40
Burn Time (Sec)

OSR No. 16-S-1432; 22
Dated 05 April 2016
CASTOR® MOTOR SERIES
LOW-COST, HIGH-RELIABILITY BOOSTERS
The CASTOR motor family was originally developed in the mid-to-late 1950s to support the
NASA Scout and Little Joe vehicles. In 1969, the CASTOR IV was developed to provide
first stage propulsion for the Athena H and was later adapted as a strap-on booster for Delta
II. The CASTOR I-IV family has a combined total of over 1,900 flights and a demonstrated
reliability of 99.95%. Since then, newer derivatives including the CASTOR IVA, IVA-XL,
and IVB have replaced the CASTOR IV motor.
• CASTOR IVA, high-performance strap-on propulsion launch vehicles
• CASTOR IVA-XL, 8-foot extended length version with 30% greater launch capability
• CASTOR IVB, TVC version with first stage, second stage, or strap-on booster application
Orbital ATK currently manufactures a complete line of first- and second-stage and strap-on
solid rocket motors. Over 50% of the U.S. space launches carry commercial satellites and
CASTOR motors are designed to provide low-cost, high-reliability propulsion to support
that access to space. Orbital ATK has used the base technology from four generations
of ballistic missile boosters and the technology and experience from expendable launch
vehicle programs to continue to add to the CASTOR series.
Development of the CASTOR 120 motor began in 1989. The CASTOR 120 was designed,
using proven technology, to meet the need for a medium-sized, reliable, solid rocket
booster. The primary goals of the program were to achieve a >0.999 reliability rating and
a 50% cost reduction. CASTOR 120 motors have served as stage one of the Lockheed
Martin Athena I and stages one and two on Athena II, and Orbital Sciences’ Taurus vehicle
used it as an initial stage (Stage 0) booster.
More recently, an upper stage CASTOR 30/30B and CASTOR 30XL have been added to
the series. CASTOR 30/30B/30XL have each flown successfully on Orbital ATK’s Antares
launch vehicle.
23
CASTOR IVA
MOTOR DIMENSIONS
Nozzle exit cone diameter, in……….....................33.6

VACUUM)
Burn time, sec.......................................................55.2
Specific impulse, lbf-sec/lbm…...........................265.3
WEIGHTS, LBM
Total motor........................................................25,737
Propellant.........................................................22,286
FIXED NOZZLE Burnout...............................................................3,239
The CASTOR IVA motor was developed in the early 1980s for
NASA. By switching to HTPB propellant (from the earlier CASTOR ........ TP-H8299, HTPB POLYMER, 20% ALUMINUM
IV), NASA was able to improve Delta II performance by 11%.
Development and qualification motors were fired in 1983. Three
additional qualification tests were conducted. Each Delta vehicle RACEWAY................................................... YES
carried nine CASTOR IVA strap-on motors until 1993. In addition, ORDNANCE................................................ YES
a straight nozzle version powered Orbital Sciences’ Prospector
TVA ...............................................................NO
suborbital vehicle and two motors flew on the Conestoga in October
1995. CASTOR IVA motors have also flown on the Lockheed TEMPERATURE LIMITS
Operation..................................................+30°-100°F
Martin Atlas IIAS, which was first flown in 1993. The four strap-on
Storage………….......................................+30°-100°F
boosters on the Atlas IIAS increase payload capacity by 1,500 lb.
Two boosters are ground-lit at ignition and two are air-ignition. Two PRODUCTION STATUS
configurations are available; -03, with an 11-degree canted nozzle,
and -04, with a 7-degree canted nozzle.
CASTOR® IVA Vaccum Thrust vs. Time
140000
120000
100000
Vacuum Thrust (lbf)
80000
60000
40000
20000

0 OSR No. 16-S-1432; 24
0 10 20 30 40 50 60
Burn Time (Seconds) Dated 05 April 2016
CASTOR IVA-XL
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................58.0
FIXED NOZZLE
WEIGHTS, LBM
The CASTOR IVA-XL motor, an 8-foot extension of the CASTOR Total motor........................................................33,031
IVA motor, was first tested in 1992. Successful qualification tests Propellant ........................................................28,906
followed in 1992 and 1993. A more recent demonstration motor Burnout...............................................................3,653
test was conducted in 1999. The Japanese H-IIA launch vehicle PROPELLANT DESIGNATION
uses modified CASTOR IVA-XL motors with 6-degree canted ........ TP-H8299, HTPB POLYMER, 20% ALUMINUM
nozzles as solid strap-on boosters (SSB). The H-IIA can use two
or four SSBs depending on mission requirements and vehicle
configuration. The first CASTOR IVA-XL SSB motors flew on the RACEWAY................................................... YES
H-IIA vehicles in 2002. ORDNANCE................................................ YES
TVA ...............................................................NO
TEMPERATURE LIMITS
Operation..................................................+30°-100°F
Storage….................................................+30°-100°F
PRODUCTION STATUS
CASTOR® IVA-XL Vaccum Thrust vs. Time
200000
180000
160000

140000
Vacuum Thrust (lbf)
120000
100000
80000
60000
40000
20000

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 OSR No. 16-S-1432; 25
CASTOR IVB
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................63.6
Maximum thrust, lbf…..................................... 119,150
Specific impulse, lbf-sec/lbm..............................267.3
WEIGHTS, LBM
Total motor........................................................25,441
Propellant.........................................................21,990
Burnout...............................................................3,254
VECTORABLE NOZZLE IN-LINE BOOSTER
The CASTOR IVB motor was the first in the series of CASTOR ....... TP-H8299, HTPB POLYMER, 20% ALUMINUM
IVA motors to incorporate TVC and a regressive thrust-time trace
for aerodynamic pressure considerations. It was developed for
the European Space Agency’s MAXUS sounding rockets and first RACEWAY................................................... YES
flew in 1991. CASTOR IVB motors have provided first stage boost ORDNANCE ............................................... YES
on all MAXUS flights. CASTOR IVB motors have also served as
TVA ............................................................. YES
first stage motors for three of the U.S. Army’s Theater Critical
Measurement Program launches in 1996 and 1997, for the U.S. Air TEMPERATURE LIMITS
Force’s ait-2 (launched from Kodiak, Alaska in 1999), for Spain’s Operation..................................................+30°-100°F
Storage……..............................................+30°-100°F
Capricornio in 1997, as first and second stages for the Conestoga
launch vehicle in 1995, and as numerous target vehicles for the PRODUCTION STATUS............................
Missile Defense Agency. ........... FLIGHT PROVEN, INACTIVE PRODUCTION

CASTOR® IVB Vaccum Thrust vs. Time
140000
120000
100000
Vacuum Thrust (lbf)
80000
60000
40000
20000
0
0 10 20 30 40 50 60 70 OSR No. 16-S-1432; 26
Burn Time (Seconds)
Dated 05 April 2016
CASTOR 30
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.....................................................149.8
Maximum thrust, lbf..........................................74,359
Total impulse, lbf-sec................................... 8,239,110
WEIGHTS, LBM
Total motor........................................................30,590
Propellant.........................................................28,098
Burnout...............................................................2,268
VECTORABLE NOZZLE IN-LINE UPPER STAGE BOOSTER PROPELLANT DESIGNATION

...... TP-H1265, HTPB POLYMER, 20% ALUMINUM
The CASTOR 30 is a low cost, robust, state-of-the-art upper stage
motor. This commercially-developed motor is 144 inches long
and nominally designed as an upper stage that can function as a RACEWAY........................................ OPTIONAL
second or third stage depending on the vehicle configuration. The ORDNANCE..................................... OPTIONAL
design of the CASTOR 30 uses all flight-proven technology and
TVA ............................................................. YES
materials.
TEMPERATURE LIMITS
Operation..................................................+30°-100°F
Storage….................................................+30°-105°F
PRODUCTION STATUS........... FLIGHT-PROVEN
CASTOR® 30 Vaccum Thrust vs. Time

80000
70000
60000
50000
Vacuum Thrust (lbf)
40000
30000
20000
10000
0
0 20 40 60 80 100 120 140 160 OSR No. 16-S-1432; 27
CASTOR 30B
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.....................................................126.7
WEIGHTS, LBM
Total motor........................................................30,800
Propellant.........................................................28,405
Burnout...............................................................2,203
........ TP-H8299, HTPB POLYMER, 20% ALUMINUM
VECTORABLE NOZZLE IN-LINE UPPER STAGE BOOSTER
The CASTOR 30B is a low cost, robust, state-of-the-art upper stage
motor. This production motor incorporates a few modifications from
the CASTOR 30, primarily a change in propellant and a longer ORDNANCE .................................... OPTIONAL
nozzle. It is 169.9 inches long and nominally designed as an upper TVA ............................................................. YES
stage that can function as a second or third stage depending on the
TEMPERATURE LIMITS
vehicle configuration. Operation..................................................+30°-100°F
Storage….................................................+30°-105°F
PRODUCTION STATUS........... FLIGHT-PROVEN
CASTOR® 30B Vaccum Thrust vs. Time

100000
90000
80000
70000
Vacuum Thrust (lbf)
60000
50000
40000
30000
20000
10000
0 Approved for Public Release

0 10 20 30 40 50 60 70
Burn Time (Seconds)
80 90 100 110 120 130
OSR No. 16-S-1432; 28
Dated 05 April 2016
CASTOR 30XL
MOTOR DIMENSIONS
MOTOR PERFORMANCE (70°F VACUUM,

VACUUM)
Burn time, sec.....................................................155.0
Effective specific impulse, lbf-sec/lbm…............294.4
Total impulse, lbf-sec.................................16,174,800
WEIGHTS, LBM
Total motor........................................................58,217
Propellant.........................................................54,949
Burnout (est.)......................................................3,069
VECTORABLE NOZZLE IN-LINE UPPER STAGE BOOSTER
.............QDL-1, HTPB POLYMER, 19% ALUMINUM
The CASTOR 30XL is a new low cost, robust, state-of-the-art upper
stage motor. CASTOR 30XL is more than a stretched version of
the CASTOR 30. The motor also capitalizes on existing common RACEWAY.....................................................NO
designs and materials, plus lessons learned on the Large Class ORDNANCE .................................................NO
Stage (LCS) I and LCS III. The motor is 235.8 inches long and
TVA ............................................................. YES
nominally designed as an upper stage that can function as a second
or third stage depending on the vehicle configuration. The nozzle TEMPERATURE LIMITS
is 8 feet long with a submerged design with a high-performance Operation....................................................+55°-85°F
expansion ratio (55.9:1) and a dual density exit cone well suited Storage….................................................+30°-100°F
PRODUCTION STATUS................FLIGHT-PROVEN,
for high altitude operation. It features an electro-mechanical TVA ....................................................... IN PRODUCTION
system with actuators, thermal battery and electronic controller.
A simulated altitude qualification static test was sucessfully
completed March 2013.

OSR No. 16-S-1432; 29
Dated 05 April 2016
CASTOR 120
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................79.4
Specific impulse, lbf-sec/lbm…..............................280
WEIGHTS, lbm
Total motor...................................................... 116,993
Propellant ......................................................107,914
VECTORABLE NOZZLE Burnout...............................................................9,097
The CASTOR 120 was designed, using proven technology, to meet PROPELLANT DESIGNATION
the need for a medium-sized, reliable solid rocket booster. While ....... TP-H1246, HTPB POLYMER, 19% ALUMINUM
primarily anticipated for in-line use, the CASTOR 120 motor can
also be configured as a strap-on booster with a moveable nozzle
and a cold-gas blowdown system TVC. The TVC system can be RACEWAY .................................................. YES
removed and the nozzle fixed. The propellant grain can also be ORDNANCE ............................................... YES
tailored to reduce thrust during max-Q pressure for high initial
TVA ............................................................. YES
thrust or for a regressive thrust to reduce acceleration. To date, the
CASTOR 120 has been used in both first stage and second stage TEMPERATURE LIMITS
applications. Operation..................................................+30°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
.......... FLIGHT PROVEN, INACTIVE PRODUCTION

OSR No. 16-S-1432; 30
Dated 05 April 2016
CASTOR 120XL
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................83.5
WEIGHTS, LBM
Total motor......................................................123,383
Propellant ...................................................... 114,194
Burnout (est).......................................................8,850
VECTORABLE NOZZLE BOOSTER
The CASTOR 120XL is a new low cost, robust, state-of-the-art ....... TP-H1246, HTPB POLYMER, 19% ALUMINUM
booster stage. CASTOR 120XL is more than just a stretched
version of the CASTOR 120. The motor also capitalizes on existing
common designs and materials, as well as lessons learned on the RACEWAY ................................................... Yes
Large Class Stage (LCS) I and LCS III. The motor is 378.3 inches ORDNANCE ................................................ Yes
long and nominally designed as a medium-sized in-line booster. It
TVA .............................................................. Yes
features an electro-mechanical TVA system with actuators, thermal
battery and electronic controller. TEMPERATURE LIMITS
Operation..................................................+30°-100°F
Storage.....................................................+30°-100°F
PRODUCTION STATUS
......................QUALIFIED THROUGH STATIC TEST,
IN PRODUCTION

OSR No. 16-S-1432; 31
Dated 05 April 2016
32
LARGE CLASS STAGE

(LCS)
HIGH-PERFORMANCE,
HIGH-RELIABILITY BOOSTERS
Orbital ATK developed and demonstrated, with the support of the U.S. Air Force, large
class (92-inch-diameter) stages (LCS) that may be applicable to multiple future common
strategic propulsion systems and potential application to a family of motors capability. The
motors include the latest in emerging technologies to enhance performance and reliability
while reducing cost. Motors have been successfully demonstrated in full-scale static test.
LCS I was developed as a first stage ground-launched booster and LCS III was developed
as an upper stage motor.
33
LCS I
MOTOR DIMENSIONS

VACUUM)
Burn time to 150 psia, sec....................................77.9
WEIGHTS, LBM
Total motor......................................................123,665
Propellant....................................................... 114,194
Burnout (est).......................................................8,884
VECTORABLE NOZZLE IN-LINE BOOSTER PROPELLANT DESIGNATION

........ TP-H1246, HTPB POLYMER, 19% ALUMINUM
LCS I is a large booster stage motor designed for first stage
use. The high-performance motor is being developed by Orbital HAZARDS CLASSIFICATION…................... 1.3
ATK for the Large Class Stage I program and uses state-of-the- RACEWAY................................................... YES
art emerging material and processing technologies for increased
ORDNANCE..................................................NO
performance and reliability with reduced cost. Orbital ATK and the
Air Force are developing the motor to meet a range of potential TVA ............................................................. YES
future strategic or launch vehicle applications. Key features of the TEMPERATURE LIMITS
motor include a domestic fiber case and an electromechanical TVC Operation..................................................+30°-100°F
system providing ±5-degree vector capability. A successful ground Storage.....................................................+30°-100°F
static test was completed on May 23, 2015. PRODUCTION STATUS......................QUALIFIED
700,000
600,000 72 F, nominal
30 F, -3 sigma
500,000 100 F, +3 sigma
Vacuum Thrust (lbf)
400,000
300,000
200,000
100,000
0
0.0 20.0 40.0 60.0 80.0 100.0
Time (sec) Approved for Public Release
OSR No. 16-S-1432; 34
Dated 05 April 2016
LCS III
MOTOR DIMENSIONS
Nozzle exit cone diameter, in..............................60.00

VACUUM)
Burn time, sec.....................................................133.0
WEIGHTS, LBM
Total motor........................................................31,307
Propellant.........................................................28,278
Inert....................................................................3,029
Burnout (est).......................................................2,845
VECTORABLE NOZZLE
LCS III is an upper stage motor designed to ignite at altitudes in ........ TP-H8299, HTPB POLYMER, 20% ALUMINUM
excess of 85,000 feet. The high-performance motor was developed
RACEWAY .................................................. YES
by Orbital ATK for the Large Class Stage III program and uses
state-of-the-art emerging material and processing technologies for ORDNANCE .................................................NO
increased performance and reliability with reduced cost. Orbital TVA ............................................................. YES
ATK and the Air Force have developed the motor to meet a range
TEMPERATURE LIMITS
of potential future applications. Key features of the motor include
Operation..................................................+30°-100°F
a domestic fiber case and an electromechanical TVC system Storage.....................................................+30°-100°F
providing ±3.5-degree vector capability. LSC III was successfully
PRODUCTION STATUS
demonstrated in late 2011 in a full-scale static test at Arnold .................... QUALIFIED AT SIMULATED ALTITUDE
Engineering Development Center in Tennessee using a vacuum
chamber designed to simulate upper atmospheric conditions.
LCS III Flight Design Predicted Thrust
100,000
90,000
80,000
70,000
Vacuum Thrust (lbf)
60,000
Maximum Predicted Thrust (100°F +3 sigma) = 96,235 lbf
(Specification Maximim = 105,000 lbf )
50,000
100F +3 sigma
40,000 70F nominal
30F -3 sigma
30,000
20,000
10,000
Note: Performance prediction has been anchored to static test results Approved for Public Release
0
0 25 50 75 100 125 150
OSR No. 16-S-1432; 35
Time (sec) Dated 05 April 2016
36
GEM MOTOR SERIES
RELIABLE, LOW-COST BOOSTERS
The Graphite Epoxy Motor (GEM) series originated with the GEM 40 motor. Orbital ATK
developed the GEM 40 for the Delta II launch vehicle to support both commercial and
government launches for The Boeing Company and other users. GEM 40 boosters increased
the launch capability of the Delta II. GEMs have demonstrated through qualification and
flight that they are the most reliable, lowest cost boosters available. Both ground and air-
start versions with a canted fixed nozzle are available for strap-on applications. In addition,
a version with a straight vectorable nozzle has been added for in-line applications.
The GEM 46 is a larger derivative of the highly reliable GEM 40. The second-generation
GEM motor has increased length, diameter, and optional vectorable nozzles. This motor
has been used on Delta III, and subsequently, Delta II Heavy launch vehicles.
GEM 60 motors were developed commercially for the Delta IV Evolved Expendable Launch
Vehicle. This third-generation 70-foot GEM motor provides auxiliary lift-off capability for
the Delta IV Medium-Plus (M+) vehicle. It is available in both fixed and vectorable nozzle
configurations. A new GEM 63 is in development for use on future launch vehicles.
State-of-the-art automation, robotics, commercial practices, and process controls are used
to produce GEMs. Cases are filament wound by computer-controlled winding machines
using high-strength graphite fiber and durable epoxy resin. Orbital ATK is the largest
producer of filament wound rocket motors in the world. Critical processes (e.g., case bond
application, propellant mixing, motor casting) are performed using an extensive network
of computerized and robotic facilities ensuring accurate control of manufacturing. The
delivered products are consistent, reliable, repeatable, high quality, competitively priced,
and delivered on time.
The GEM family of motors includes:

• GEM 40, multiple configurations
37
GEM 40 (GROUND IGNITED)
MOTOR DIMENSIONS
MOTOR PERFORMANCE (73°F NOMINAL)

Burn time, sec.......................................................63.3
Burn time average thrust, lbf.......................... 112,200
WEIGHTS, LBM
Total motor........................................................28,577
Propellant ........................................................25,940
FIXED NOZZLE, GROUND-IGNITED Burnout...............................................................2,429
The 40-inch-diameter graphite epoxy motor (GEM 40) is a strap-on PROPELLANT DESIGNATION
booster system developed to provide thrust augmentation for the
Delta II launch vehicle. The GEM 40 features an IM7/55A graphite HAZARDS CLASSIFICATION…................... 1.3
epoxy motor case, an aramid-filled EPDM insulator, and a 10-degree
RACEWAY................................................... YES
canted, fixed nozzle assembly. The nozzle has a high performance
3-D carbon-carbon throat and carbon phenolic insulators. Ignition ORDNANCE..................................................NO
is accomplished with a forward-mounted pyrogen igniter. The GEM TVA ...............................................................NO
40 motor also includes a raceway assembly, forward interstage,
TEMPERATURE LIMITS
and aft attach ball interfaces. The GEM 40 has flown on Delta II Operation..................................................+30°-100°F
vehicles since 1991. Storage.....................................................+30°-100°F
PRODUCTION STATUS
Ground-Start Motor Performance. 73 Deg F Nominal

160000.0
120000.0
Vacuum Thrust (lbf)
60000.0
40000.0
0.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0
Time (Sec) OSR No. 16-S-1432; 38
Dated 05 April 2016
GEM 40 (AIR IGNITED)
MOTOR DIMENSIONS

Burn time, sec.......................................................63.3
Effective specific impulse, lbf-sec/lbm................283.4
Burn time average thrust, lbf.......................... 116,050
WEIGHTS, LBM
Total motor........................................................28,883
FIXED NOZZLE, AIR-IGNITED Propellant ........................................................25,940
Burnout...............................................................2,649
The 40-inch-diameter graphite epoxy motor (GEM 40) is a strap-
on booster system developed to provide thrust augmentation for PROPELLANT DESIGNATION
the Delta II launch vehicle. The GEM 40 features an IM7/55A .............. QDL-1, HTPB POLYMER, 19% ALUMINUM
graphite composite motor case, an aramid-filled EPDM insulator, HAZARDS CLASSIFICATION…................... 1.3
and a 10-degree canted, fixed nozzle assembly. For the Delta II
RACEWAY................................................... YES
nine-motor configuration, six motors are ignited on the ground
and three in the air. The air-start (altitude-ignited) GEM 40 motor ORDNANCE..................................................NO
configuration has a lengthened nozzle exit cone with higher TVA................................................................NO
expansion ratio, exit-plane-mounted nozzle closure system that is
TEMPERATURE LIMITS
ejected at air-start motor ignition, and a different external insulation
Operation..................................................+30°-100°F
scheme. The GEM 40 has flown on Delta II vehicles since 1991. Storage.....................................................+30°-100°F
PRODUCTION STATUS

OSR No. 16-S-1432; 39
Dated 05 April 2016
GEM 40VN
MOTOR DIMENSIONS

Burn time, sec.......................................................64.6
Maximum thrust…..........................................139,036
WEIGHTS, LBM
Total motor........................................................28,886
Propellant ........................................................25,940
Burnout...............................................................2,607
VECTORABLE NOZZLE, GROUND-IGNITED, IN-LINE MOTOR
The GEM 40VN booster is derived from the successful GEM RACEWAY................................................... YES
40 booster. The GEM 40VN maintains the same loaded motor ORDNANCE .................................................NO
configuration as the GEM 40 with a design modification to the nozzle
TVA ............................................................. YES
assembly to provide ±6-degree thrust vector capability. Air-ignition
with extended length nozzle can also be readily provided. The GEM TEMPERATURE LIMITS
Operation..................................................+30°-100°F
40VN can be used in both in-line and strap-on booster applications.
Storage.....................................................+30°-100°F
A version of this motor has been developed and was qualified for
use on the Boost Vehicle/Boost Vehicle Plus (BV/BV+) configuration PRODUCTION STATUS
for the Ground-based Midcourse Defense (GMD) missile interceptor
program.

Vacuum Thrust (lbf)

Burn Time (Sec) OSR No. 16-S-1432; 40
Dated 05 April 2016
GEM 46 (FIXED, GROUND-IGNITED)
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................75.9
Maximum thrust…..........................................198,800
WEIGHTS, LBM
Total motor........................................................41,590
Propellant ........................................................37,180
FIXED NOZZLE, GROUND-IGNITED Burnout...............................................................4,050
The larger diameter, extended length graphite epoxy motor (GEM PROPELLANT DESIGNATION
46) is a strap-on booster system originally developed to increase ................ QEM, HTPB POLYMER, 19% ALUMINUM
the payload-to-orbit capability of the Delta III launch vehicle. The HAZARDS CLASSIFICATION…................... 1.3
GEM 46 features an IM7/55A graphite composite motor case, an
RACEWAY .................................................. YES
aramid-filled EPDM insulator, and a 10-degree canted, fixed nozzle
assembly. The nozzle has a high performance 3-D carbon-carbon ORDNANCE .................................................NO
throat and carbon phenolic insulators. Ignition is accomplished TVA ...............................................................NO
with a forward-mounted pyrogen igniter. The GEM 46 booster
TEMPERATURE LIMITS
includes raceway assembly, forward interstage, and aft attach ball Operation..................................................+30°-100°F
interfaces. GEM 46 motors have been used on both the Delta II Storage.....................................................+30°-100°F
Heavy and Delta III launch vehicles.
PRODUCTION STATUS
.......... FLIGHT-PROVEN, INACTIVE PRODUCTION

Vacuum Thrust (lbf)

Burn Time (Sec) OSR No. 16-S-1432; 41
Dated 05 April 2016
GEM 46 (VECTORABLE, GROUND-IGNITED)
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................76.9
WEIGHTS, LBM
Total motor........................................................42,196
Propellant.........................................................37,180
VECTORABLE NOZZLE, GROUND-IGNITED Burnout...............................................................4,656
The larger diameter, extended length graphite epoxy motor (GEM PROPELLANT DESIGNATION
................ QEM, HTPB POLYMER, 19% ALUMINUM
46) is a strap-on booster system originally developed to increase
the payload-to-orbit capability of the Delta III launch vehicle. The HAZARDS CLASSIFICATION…................... 1.3
GEM 46 features an IM7/55A graphite composite motor case RACEWAY................................................... YES
and an aramid-filled EPDM insulator. This configuration has a
ORDNANCE .................................................NO
5-degree canted, ±5-degree moveable nozzle assembly with a
high performance 3-D carbon-carbon throat and carbon phenolic TVA ............................................................. YES
insulators. Ignition is accomplished with a forward mounted pyrogen TEMPERATURE LIMITS
igniter. This GEM 46 booster includes TVA, raceway assembly, Operation..................................................+30°-100°F
forward interstage, and aft attach ball interfaces. Three of these Storage.....................................................+30°-100°F
vectorable-nozzle ground-ignited motors were used on each PRODUCTION STATUS
Delta III. ........... FLIGHT-PROVEN, INACTIVE PRODUCTION

Vacuum Thrust (lbf)
Burn Time (Sec) Approved for Public Release

OSR No. 16-S-1432; 42
Dated 05 April 2016
GEM 46 (FIXED, AIR-IGNITED)
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................75.9
WEIGHTS, LBM
Total motor........................................................42,039
Propellant ........................................................37,180
FIXED NOZZLE, AIR-IGNITED Burnout...............................................................4,397
The larger diameter, extended length graphite epoxy motor (GEM
46) is a strap-on booster system originally developed to increase
................ QEM, HTPB POLYMER, 19% ALUMINUM
the payload-to-orbit capability of the Delta III launch vehicle. The
GEM 46 features an IM7/55A graphite composite motor case, an HAZARDS CLASSIFICATION…................... 1.3
aramid-filled EPDM insulator, and a 10-degree canted, fixed nozzle RACEWAY .................................................. YES
assembly. The nozzle has a high performance 3-D carbon-carbon
ORDNANCE .................................................NO
throat and carbon phenolic insulators. This air-start (altitude-
ignited) GEM 46 motor configuration has a lengthened nozzle TVA ...............................................................NO
exit cone with a higher expansion ratio. Ignition is accomplished TEMPERATURE LIMITS
with a forward-mounted pyrogen igniter. The GEM 46 booster Operation..................................................+30°-100°F
includes raceway assembly, forward interstage, and aft attach ball Storage.....................................................+30°-100°F
interfaces. This GEM 46 motor has been used on both the Delta II PRODUCTION STATUS
Heavy and Delta III launch vehicles. ........... FLIGHT-PROVEN, INACTIVE PRODUCTION

Vacuum Thrust (lbf)

Burn Time (Sec)
OSR No. 16-S-1432; 43
Dated 05 April 2016
GEM 60 (VECTORABLE)
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................90.8
Maximum thrust…..........................................277,852
Specific impulse, lbf-sec/lbm.................................274
WEIGHTS, LBM
Total motor........................................................74,185
Propellant ........................................................65,472
Burnout...............................................................8,203
VECTORABLE NOZZLE
The 60-inch-diameter graphite epoxy motor (GEM 60) is a strap- PROPELLANT DESIGNATION
................ QEY, HTPB POLYMER, 19% ALUMINUM
on booster system developed to increase the payload-to-orbit
capability of the Delta IV Medium-Plus (M+) launch vehicles. Two HAZARDS CLASSIFICATION…................... 1.3
and four strap-on motor configurations of the GEM 60 can be RACEWAY .................................................. YES
flown on the Delta IV M+ vehicles. The GEM 60 features an IM7R/
ORDNANCE................................................ YES
CLRF-100 graphite composite motor case and aramid-filled EPDM
insulator. This configuration has a 5-degree canted, ±5-degree TVA ............................................................. YES
moveable nozzle assembly. The nozzle has a high performance TEMPERATURE LIMITS
3-D carbon-carbon throat, EPDM, and carbon phenolic insulators. Operation..................................................+30°-100°F
Ignition is accomplished with a forward-mounted pyrogen igniter. Storage.....................................................+30°-100°F
The GEM 60 booster includes a raceway assembly, forward PRODUCTION STATUS
interstage, aft attach ball interfaces, nosecone, customer-furnished ......................FLIGHT-PROVEN, IN PRODUCTION
material (CFM) ordnance/cabling, and closeout hardware. This
motor's first flight occured in November 2002 and was the first
flight of the Air Force's Evolved Expendable Launch Vehicle (EELV)
program.
Vectorable Nozzle
300000
250000
200000
Thrust, lbf
150000
100000
50000
0 Approved for Public Release
0 20 40 60 80 100 120 OSR No. 16-S-1432; 44
Time, seconds Dated 05 April 2016
GEM 60 (FIXED)
MOTOR DIMENSIONS

VACUUM)
Burn time, sec.......................................................90.8
Maximum thrust…..........................................280,767
Specific impulse, lbf-sec/lbm.................................275
WEIGHTS, LBM
Total motor........................................................73,156
Propellant ........................................................65,472
Burnout...............................................................7,207
FIXED NOZZLE PROPELLANT DESIGNATION

................ QEY, HTPB POLYMER, 19% ALUMINUM
The 60-inch-diameter graphite epoxy motor (GEM 60) is a strap-
on booster system developed to increase the payload-to-orbit HAZARDS CLASSIFICATION…................... 1.3
capability of the Delta IV Medium-Plus (M+) launch vehicles. Two RACEWAY................................................... YES
and four strap-on motor configurations of the GEM 60 can be
ORDNANCE ............................................... YES
flown on the Delta IV M+ vehicles. The GEM 60 features an IM7R/
CLRF-100 graphite composite motor case and an aramid-filled TVA................................................................NO
EPDM insulator. This configuration has a 10-degree canted, fixed TEMPERATURE LIMITS
nozzle assembly. The nozzle has a high performance 3-D carbon- Operation..................................................+30°-100°F
carbon throat, EPDM, and carbon phenolic insulators. Ignition is Storage.....................................................+30°-100°F
accomplished with a forward-mounted pyrogen igniter. The GEM PRODUCTION STATUS
60 booster includes a raceway assembly, forward interstage, aft ......................FLIGHT-PROVEN, IN PRODUCTION
attach ball interfaces, nosecone, customer-furnished material
(CFM) ordnance/cabling, and closeout hardware. This motor’s first
flight occurred in December 2009.

OSR No. 16-S-1432; 45
Dated 05 April 2016
GEM 63
MOTOR DIMENSIONS
Overall motor length (incl. nozzle/fairing, etc) in..789.3

VACUUM)
Burn time, sec............................................................ *
Maximum thrust,lbf.................................................... *
Effective specific impulse, lbf-sec/lbm....................... *
Total impulse, lbf-sec................................................. *
Burn time average thrust, lbf..................................... *
WEIGHTS, LBM
Total motor................................................................. *
Propellant ................................................................. *
FIXED NOZZLE BOOSTER Burnout (est).............................................................. *
The GEM 63 is a new low cost, robust, state-of-the-art strap-on
booster stage being designed for use on future launch vehicles. ............... QDL, HTPB POLYMER, 19% ALUMINUM
The motor is an evolution of the current GEM motors. It capitalizes
on existing common designs and materials, plus lessons learned
and low cost manufacturing processes advanced from prior GEM, RACEWAY................................................... YES
Orion, and CASTOR motors. The motor is 789.3 inches long and ORDNANCE ............................................... TBD
nominally designed as a strap-on booster for medium to large-sized
TEMPERATURE LIMITS
launch vehicles. It features a fixed nozzle canted at three degrees.
Operation....................................................+40°-90°F
The motor is currently in development and as such specifications Storage.....................................................+30°-100°F
may change. Full-scale static test and qualifiction are scheduled
PRODUCTION STATUS
for mid-2018.
............................................... IN DEVELOPMENT
* Please contact us for current information

OSR No. 16-S-1432; 46
Dated 05 April 2016
GEM 63XL
MOTOR DIMENSIONS
Overall motor length (incl. nozzle/fairing, etc) in..862.0

VACUUM)
Burn time, sec............................................................ *
Maximum thrust,lbf.................................................... *
Effective specific impulse, lbf-sec/lbm....................... *
Total impulse, lbf-sec................................................. *
FIXED NOZZLE BOOSTER
Burn time average thrust, lbf..................................... *
The GEM 63XL is a new low cost, robust, state-of-the-art strap-on
booster stage being designed for use on future launch vehicles. WEIGHTS, LBM
Total motor................................................................. *
The motor is an evolution of the current GEM motors. It capitalizes
Propellant ................................................................. *
on existing common designs and materials, plus lessons learned Burnout (est).............................................................. *
and low cost manufacturing processes advanced from prior GEM,
Orion, and CASTOR motors. The GEM 63XL is being co-developed
............... QDL, HTPB POLYMER, 19% ALUMINUM
with the GEM 63 to share several common components and provide
more thrust and impulse with a longer composite case. The motor HAZARDS CLASSIFICATION…................... 1.3
is 862.0 inches long and nominally designed as a strap-on booster RACEWAY................................................... YES
for large-sized launch vehicles. It features a fixed nozzle canted at
ORDNANCE ............................................... TBD
three degrees. The motor is currently in development and as such
specifications may change. Full-scale static test and qualifiction TEMPERATURE LIMITS
Operation....................................................+40°-90°F
are scheduled for mid-2018.
Storage.....................................................+30°-100°F
PRODUCTION STATUS
....................................................IN DEVELOPMENT
* Please contact us for current information

OSR No. 16-S-1432; 47
Dated 05 April 2016
48
SOLID ROCKET MOTOR

UPGRADE (SRMU)
The SRMU was developed for the U.S. Air Force and Lockheed Martin to increase the
launch capability of the Titan IVB Space Launch Vehicle (retired). This vehicle supplies
access to space for critical national security as well as for civil payloads and can be
launched from the East and West Coasts. SRMU motor segments are manufactured using
state-of-the-art automation, robotics, and process controls for a consistent, reliable, high-
quality product.
The SRMU increased the launch capability of the Titan IVB Space Launch Vehicle.
Designed to take advantage of proven, off-the-shelf technologies, the SRMU system
provides 25% increased performance and heavier lift capability than the boosters used on
earlier configurations.
The SRMU is a three-segment, 10.5-ft-diameter solid rocket motor. A flight set consists of
two SRMUs. When fully assembled, each SRMU is approximately 112 ft. tall and weighs
over 770,000 lb. With the SRMU, the Titan IVB low earth orbit payload exceeds 47,000 lb
and its geosynchronous orbit payload capability ranges up to 12,700 lb.
SRMU motor segments are manufactured using state-of-the-art automation, robotics, and
process controls. Cases are filament wound with computer-controlled winding machines
using a composite of high-strength fiber and durable epoxy resin. SRMUs are then cast
and finished using an extensive network of computers and robotics, which enables highly
accurate control of critical manufacturing processes for a consistent, reliable, high-quality
product.
In 1997, Titan IVB launched the Cassini spacecraft and the Huygens Probe on an
international mission to study Saturn. Weighing roughly 13,000 lb, the Cassini spacecraft
is one of the largest ever launched. The spacecraft entered Saturn’s orbit on July 1, 2004.
49
SRMU
MOTOR DIMENSIONS
Motor diameter, in..................................................126
Motor length, in...................................................1,349

VACUUM)
Burn time, sec.....................................................135.7
Average chamber pressure, psia........................859.5
Total impulse, lbf-sec...............................195,476,128
Burn time average thrust, lbf.......................1,440,502
NOZZLE
Housing material
................... 4340 steel with graphite epoxy overwrap
Exit diameter, in..................................................128.6
Expansion ratio, average......................................15.7
STRAP-ON BOOSTER/SEGMENT
With the solid rocket motor upgrade (SRMU), the Titan IVB low WEIGHTS, LBM
Total loaded ..................................................776, 038
earth orbit payload exceeds 47,800 lb and its geosynchronous
Propellant ......................................................695,427
orbit payload capability ranges up to 12,700 lb (East Coast launch) Case ................................................................35,075
and the low earth polar orbit capability ranges up to 38,000 lb Nozzle ..............................................................14,706
(West Coast launch). The SRMU successfully flew its first mission Other.................................................................30,830
in 1997 with subsequent missions flown for the Air Force’s Burnout............................................................. 80,611
Milstar and Defense Support Program satellites, the National PROPELLANT DESIGNATION
Reconnaissance Organization’s military intelligence satellites, ...........................................QDT, 88% SOLIDS HTPB
and NASA’s Cassini satellite. The SRMU is a three-segment solid HAZARDS CLASSIFICATION....................... 1.3
rocket motor, manufactured in segments, shipped to the launch
RACEWAY................................................... YES
site, and stacked at the site.
ORDNANCE ............................................... YES
TVA ............................................................. YES

TEMPERATURE LIMITS
Operation....................................................25°-100°F
PRODUCTION STATUS.........................................
.............. FLIGHT PROVEN, OUT OF PRODUCTION
Vacuum Thrust (lbf)
Burn Time (Sec)

OSR No. 16-S-1432; 50
Dated 05 April 2016
REUSABLE SOLID
ROCKET MOTOR (RSRM)
In 1974, NASA chose Thiokol (now part of Orbital ATK) to design and build the solid rocket
motors that would boost the fleet of orbiters from the launch pad to the edge of space. With
the maiden flight of Columbia (STS-1) in 1981, a new era in space exploration had begun.
The RSRM is the largest solid rocket motor ever to fly and the only solid rocket motor rated
for human flight. It was the first booster designed for reuse; reusability of the RSRM case
was an important cost-saving factor in the nation’s space program. The boosters provided
80 percent of the thrust needed to launch NASA’s Space Shuttle. Each RSRM consists
of four solid propulsion segments, TVC, and an aft exit cone assembly. After burnout at
approximately two minutes, the boosters were separated pyrotechnically and fell into the
Atlantic for recovery. The motors were cleaned, disassembled, and returned to Utah for
refurbishment and reloading. Motor segments are designed for reuse on up to 20 flights.
The RSRMs were also designed with the capability to be used as strap-on boosters for
other heavy-lift launch vehicle applications.
51
RSRM
MOTOR DIMENSIONS
Motor diameter, in...............................................146.1
Motor length, in..............................................1,513.49

VACUUM)
Burn time, sec.....................................................122.2
Web time average thrust, lbf........................2,430,456
NOZZLE
Housing material........................................D6AC steel
Exit diameter, in................................................149.64
WEIGHTS, LBM
NASA SPACE SHUTTLE MOTOR
Total loaded.................................................1,255,334
Each motor is just over 126-ft long and 12-ft in diameter. The entire Propellant ...................................................1,106,059
booster (including nose cap, frustum, and forward and aft skirts) is Case ................................................................98,748
approximately 149-ft long. Of the motor’s total weight of 1,252,000 Nozzle ..............................................................23,942
lb, propellant accounts for 1,107,000 lb. Other.................................................................26,585
Burnout...........................................................144,206
Each Shuttle launch required the boost of two RSRMs. From
ignition to end of burn, each RSRM generates an average thrust of PROPELLANT DESIGNATION
.............. TP-H1148, PBAN POLYMER, 86% SOLIDS
2,600,000 lb and burns for approximately 123.6 seconds. By the
time the twin RSRMs have completed their task, the Space Shuttle HAZARDS CLASSIFICATION…................... 1.3
orbiter has reached an altitude of 24 nautical miles and is traveling TEMPERATURE LIMITS
at a speed in excess of 3,000 miles per hour. Operation.....................................................+40º-90ºF
Engineers direct approximately 110,000 quality control PRODUCTION STATUS
inspections on each RSRM flight set. RSRMs are also static tested .............. FLIGHT PROVEN, OUT OF PRODUCTION
as part of the quality assurance and development process.
4 1000
Millions
P
3.6 900
3.2 F 800
2.8 700
Head-End Chamber Pressure (psia)
Vacuum Thrust (lbf)
2.4 600
2 500
1.6 400
1.2 300
0.8 200
0.4 100
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
0
Time (sec) OSR No. 16-S-1432; 52
Dated 05 April 2016
RSRM DERIVATIVES
VECTORABLE NOZZLE HEAVY-LIFT BOOSTERS
Reusable solid rocket motor (RSRM) derivative boosters have the demonstrated reliability
of the human-rated Space Shuttle system and the experience provided by a long heritage
of successful flight. Examining recovered RSRM hardware and using RSRM program
history has allowed for continuous reliability assessments and improvement to RSRM
production hardware. Additional enhancements have been developed and matured through
the Ares/Space Launch System (SLS) five-segment reusable solid rocket motor (RSRMV)
programs. While RSRM production has ended, sustained RSRMV production for the SLS
provides synergistic cost savings and reliable, qualified material sources to also support
derivative boosters. Finally, a complete family of booster stacks in increments as small as
a half segment allows customized and efficient payload matching. These derivative motors
can be used as a first stage motor or a strap-on booster.
The existing NASA-heritage designs and processes may also be combined with commercial
elements to provide high-thrust, safe, efficient, and capable first stage propulsion.
53
1-SEGMENT RSRM
MOTOR DIMENSIONS
FIXED/VECTORABLE NOZZLE Motor diameter, in...............................................146.1
Motor length, in...................................................499.6

VACUUM)
Burn time, sec..................................................... 115.8
NOZZLE
Exit diameter, in....................................................93.8
Expansion ratio, average....................................10.75
WEIGHTS, LBM
Total loaded....................................................404,601
Propellant ......................................................336,231
Case ................................................................30,867
Nozzle ..............................................................16,000
Other.................................................................21,503
Burnout.............................................................66,072
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
............. TP-H1148, PBAN POLYMER, 86% SOLIDS
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS
.... CONCEPT BASED ON A PRODUCTION MOTOR

OSR No. 16-S-1432; 54
Dated 05 April 2016
1.5-SEGMENT RSRM
MOTOR DIMENSIONS
FIXED/VECTORABLE NOZZLE Motor diameter, in...............................................146.1
Motor length, in...................................................697.0

VACUUM)
Burn time, sec..................................................... 117.0
NOZZLE
Exit diameter, in.................................................. 113.3
Expansion ratio, average...................................... 11.8
WEIGHTS, LBM
Total loaded....................................................558,993
Propellant ......................................................476,496
Case ................................................................41,666
Nozzle ..............................................................16,000
Other.................................................................24,831
Burnout.............................................................79,286
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS

OSR No. 16-S-1432; 55
Dated 05 April 2016
2-SEGMENT RSRM
FIXED/VECTORABLE NOZZLE MOTOR DIMENSIONS
Motor length, in...................................................860.0

VACUUM)
Burn time, sec..................................................... 114.1
NOZZLE
Exit diameter, in.................................................. 118.7
WEIGHTS, LBM
Total loaded....................................................715,659
Propellant ......................................................619,003
Case ................................................................52,465
Nozzle ..............................................................16,000
Other.................................................................28,191
Burnout.............................................................93,075
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS

OSR No. 16-S-1432; 56
Dated 05 April 2016
2.5-SEGMENT RSRM
FIXED/VECTORABLE NOZZLE MOTOR DIMENSIONS
Motor length, in................................................1,037.0

VACUUM)
Burn time, sec..................................................... 113.2
NOZZLE
Exit diameter, in..................................................133.7
Expansion ratio, average...................................... 11.1
WEIGHTS, LBM
Total loaded....................................................867,215
Propellant ......................................................758,990
Case ................................................................62,716
Nozzle ..............................................................17,000
Other.................................................................28,509
Burnout...........................................................103,487
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS

OSR No. 16-S-1432; 57
Dated 05 April 2016
3-SEGMENT RSRM
1156.2 in. MOTOR DIMENSIONS
146.9 in. 152.6 in.
Motor length, in................................................1,156.2

206.5 in.
VACUUM)
Burn time, sec.....................................................133.7
VECTORABLE NOZZLE, GROUND LAUNCH Total impulse, lbf-sec...............................223,000,000
This design combines existing NASA-heritage designs and Burn time average thrust, lbf.......................1,671,034
processes with commercial elements to meet market-driven
NOZZLE
demands for competitive, capable, and reliable propulsion. The Housing material........................................D6AC steel
stage configuration consists of motor segments based on Ares Exit diameter, in..................................................149.6
and Space Launch System (SLS) upgrades to the Shuttle RSRM, Expansion ratio, average......................................7.89
an RSRM-design nozzle, and new, lower cost, aft skirt and TVC
WEIGHTS, lbm
system. The benefits to using the Ares/SLS RSRMV motor
Total loaded....................................................981,686
segments include non-asbestos insulation, common materials Propellant ......................................................843,286
and processes in the factory, and improved performance. The Case ................................................................77,641
new non-asbestos insulation performs better, which allows thinner Nozzle ..............................................................24,241
insulation and hence more propellant loading. The new TVC Other.................................................................36,519
system provides ±5-degree capability and is based on a prototype Burnout...........................................................135,310
electro-hydrostatic system designed for the Titan booster and PROPELLANT DESIGNATION
leverages recent commercial TVC component development and ......... TP-H1148 IV, PBAN POLYMER, 86% SOLIDS
qualification supporting CASTOR 30 motors. HAZARDS CLASSIFICATION…................... 1.3
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS

OSR No. 16-S-1432; 58
Dated 05 April 2016
4-SEGMENT RSRM
1476.3 in.
MOTOR DIMENSIONS
146.9 in. 152.6 in.
Motor length, in................................................1,476.3
206.5 in.

VACUUM)
VECTORABLE NOZZLE GROUND LAUNCH
Burn time, sec.....................................................132.8
This design combines existing NASA-heritage designs and Average chamber pressure, psia...........................572
processes with commercial elements to meet market-driven Total impulse, lbf-sec...............................298,000,000
demands for competitive, capable, and reliable propulsion. The Burn time average thrust, lbf.......................2,247,233
stage configuration consists of motor segments based on Ares and
NOZZLE
SLS upgrades to the Shuttle RSRM, an RSRM-design nozzle, and Housing material........................................D6AC steel
new, lower cost aft skirt and TVC system. The benefits to using Exit diameter, in..................................................149.6
the Ares/SLS RSRMV motor segments include non-asbestos Expansion ratio, average......................................7.72
insulation, common materials and processes in the factory, and
WEIGHTS, lbm
improved performance. The new non-asbestos insulation performs
Total loaded.................................................1,278,078
better, which allows thinner insulation and hence more propellant Propellant ................................................... 1,114,155
loading. The new TVC system provides ±5-degree capability and is Case ................................................................99,326
based on a prototype electro-hydrostatic system designed for the Nozzle ..............................................................24,140
Titan booster and leverages recent commercial TVC component Other.................................................................40,456
Burnout...........................................................158,604
development and qualification supporting CASTOR 30 motors.
........TP-H1148 VIII, PBAN POLYMER, 86% SOLIDS
TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
PRODUCTION STATUS

OSR No. 16-S-1432; 59
Dated 05 April 2016
5-SEGMENT RSRM
MOTOR DIMENSIONS
Motor length, in................................................1,864.7

VACUUM)
Burn time, sec.....................................................131.9
NOZZLE
Throat housing material.............................D6AC steel
Exit diameter, in................................................152.55
WEIGHTS, LBM
Total loaded.................................................1,616,123
Propellant ...................................................1,427,807
VECTORABLE NOZZLE GROUND LAUNCH Case ..............................................................127,843
Orbital ATK and NASA are developing a five-segment RSRMV Nozzle ..............................................................24,029
booster derivative that will generate a maximum thrust of Other.................................................................36,444
Burnout...........................................................181,480
approximately 3.6 million pounds. The five-segment RSRMV is
also upgraded to incorporate newer technologies and materials PROPELLANT DESIGNATION
such as non-asbestos insulation that provides cost and weight .TP-H1148 TPYE VIII, PBAN POLYMER, 86% SOLIDS
savings. HAZARDS CLASSIFICATION…................... 1.3

Originally baselined for Ares I/V under the Constellation TEMPERATURE LIMITS
Operation.....................................................+40º-90ºF
program, the RSRMV is currently slated to be utilized as the
baseline design for the initial flights under NASA’s Space Launch PRODUCTION STATUS
........DEVELOPMENT TESTED, IN QUALIFICATION
System (SLS) architecture. Orbital ATK has conducted three
successful development and one qualification static tests. A
second qualification test is in preparation for mid-2016.

OSR No. 16-S-1432; 60
Dated 05 April 2016
STAR™ MOTOR SERIES
PERFORMANCE, CAPABILITY, INTERFACE

TAILORING, AND TECHNICAL SUPPORT SERVICES
FOR STAR MOTORS
Orbital ATK’s STAR, ASAS, Orion, CASTOR, GEM, and RSRM motors span a significant
range of impulse capability. Specific applications often require design tailoring and technical
support to best achieve mission goals.
The sections that follow describe how Orbital ATK tailors ballistic performance, provides
mission specific capabilities, and/or delivers technical support for STAR series space
motors. Similar performance tailoring and support can be provided for our other products.
Tailor Ballistic Performance. Specific examples include efforts to achieve the following
goals:
• Increase propellant loading and thus total impulse by stretching motor length
• Cut back or off-load the propellant grain to reduce propellant weight and total impulse
• Limit peak thrust/acceleration levels on the payload/spacecraft by altering propellant
formulations and/or grain geometry and/or operating pressure
• Modify the nozzle to adjust throat erosion and thrust profiles
• Incorporate an exit cone extension (e.g., a gas-deployed skirt) to enhance expansion ratio
and overall performance
• Minimize performance variation by machining propellant grains to precise weight tolerances
and by providing thermal systems to maintain propellant grain temperature
• Incorporate mission-specific propellants that provide desired energy levels, environmental
compatibility, and/or exhaust characteristics
Provide Desired Mission-Specific Capabilities. Orbital ATK is pleased to support

our customers with designs that will meet mission-specific conditions. This includes
incorporation of additional capabilities and/or providing design compliance with customer-
specified flight envelopes, interfaces, and environments. Examples include the following:
• Use of alternative case materials (steel, aluminum, titanium, composite)
• Qualification to new environments
• Use of proven materials to ensure space storability
61
• Exit cone length truncation or shortening to fit within a restricted envelope

• Provision of active thrust vector control (TVC) for vehicle steering
• Incorporation of a reaction control system (RCS) for motor and stage pointing
• Furnishing of thermal protection of spacecraft structures from the heat of motor operation
through postfiring heat soak
• Provision of thermal management, using heaters and/or blankets prior to operation
• Integration of motors/stages with spin and de-spin motors and collision avoidance systems
• Design of stages with associated command timers and/or avionics and power systems and
related software to enable autonomous stage operation
• Integration of advanced ordnance components for motor initiation, stage separation, and flight
termination
• Accommodation of specific spacecraft structural interfaces including incorporation of tabs,
skirts, and/or complete interstage structures fabricated from metal or composite material
• Movement or modification of attachment features as required to mate with space-craft/
payload
Technical Support. Orbital ATK can provide technical alternatives and support for design
and flight efforts, including the following:
• Inert mass simulators for system ground tests
• Technical trades on critical design parameters needed for overall system design
• System engineering data and analysis support including performance modeling
• Test and analysis to demonstrate operational capability under new environmental conditions
(temperatures, spin conditions, space aging, etc.)
• Logistic, personnel, and technical support for motor shipping, packaging, and integration
with the spacecraft or launch vehicle at the launch site including, but not limited to, preparing
field handling manuals and providing ground support equipment (GSE) for the motor (e.g.,
turnover stands, handling stands, and leak test equipment)
Orbital ATK has the experience to modify our basic motor designs and can design
completely new motors at minimum risk to support specific flight applications (see
following figure). We are also prepared to provide required technical support for all of our
motor, ordnance, and stage products.
STAR 30BP STAR 30E
STAR 30BP Motor Was Stretched 7 in. to Yield the STAR 30E
62
Documentation and Field Support. Orbital ATK has prepared and provided to various
customers documentation and field support for launches from Cape Canaveral Air Force
Station (CCAFS) Kennedy Space Center (KSC), Vandenberg Air Force Base, Kodiak Launch
Complex, Tanegashima Space Center, Xi Chang, Wallops Flight Facility, Fort Churchill,
San Marcos Test Center, Kwajelin Test Center, China Lake Test Center, and Kourou. For
most programs, Orbital ATK prepares the documents; conducts a training session with the
responsible ground crew; participates in auditing and modifying the documents to comply
with on-site equipment, facilities, and safety practices; and prepares the final documents
prior to delivery of the first flight motor in the field, thereby facilitating safe and efficient
handling of the first flight system. Orbital ATK can also be enlisted to review and assess
customer-prepared procedures for the safe handling of our rocket motors.
Field Support. Orbital ATK has the trained personnel to lead, instruct, and assist ground
crews for receipt, maintenance, inspection, checkout, and assembly of motors and
ordnance items. Training or instructional sessions are often of value to customers and
launch range personnel and can be conducted at Orbital ATK or on-site.
Instructional Field Handling Documentation. The table below lists the procedural
documents that can be prepared at customer request for each motor. Many motor
programs have adopted these materials for use in the field as supplemental information in
the preparation of vehicle stage or spacecraft propulsion units for inspection, buildup, and
assembly at the various launch sites.
Typical Instructional Documentation
Document Type Description

Engineering Instruction Describes proper unpacking, handling, storage, and maintenance of the rocket motor in the field (safety
precautions)
X-ray Inspection Procedure Establishes radiographic inspection procedure to be used for preflight evaluation using launch site
facilities
Inspection Procedure Delineates proper use of equipment and procedures for verification of motor component integrity
Safe-and-Arm (S&A) Describes electrical checkout of live S&A devices
Checkout Procedure
Ordnance Assembly Delineates proper procedure for checkout and installation of squibs, through-bulkhead initiators, explosive
Procedure transfer assemblies, and S&A devices
Motor Final Inspection and Delineates inspection and preflight buildup of the rocket motor. This procedure can contain many or all
Assembly Procedure other instructional documents for field support and surveillance
Safety Plan Provides information on the proper safety procedures for handling of explosive devices
Handling Equipment Describes conduct of periodic proof or load tests to verify equipment adequacy. Delineates proper
Maintenance Procedure procedures for maintenance of equipment
Motor Flight Instrumentation Describes proper procedures for installation and checkout of items such as pressure transducers, strain
Installation and Checkout gauges, etc. Delineates precautions and need for testing following installation
Other Instruction Many systems have unique requirements for ancillary equipment or ordnance items. Procedures can be
prepared to meet almost any system need (e.g., spin balancing)
63
Motor Ground Support Equipment (GSE). In addition to shipping containers, we can

provide a variety of GSE for use in handling, inspection, and assembly of the rocket motor
and ordnance devices. Orbital ATK also designs mission-specific equipment for installation
of the motor into the spacecraft or stage. Typical GSE available includes the following:
• Shipping containers
• Turnover stands
• Inert mass simulators
• Leak test equipment
In-Transit Instrumentation. Space motors are sensitive to temperature, humidity, and

shock loads. Monitoring of the environmental conditions during transportation of space
motors is critical. Several standard and proven devices are available. We can also
accommodate special problems, such as long periods of transit. Some of the items readily
available are:
• Temperature recorders
• Shock indicators
• Humidity indicators
Generally, Orbital ATK personnel have monitored all activities during development,
qualification, and lot acceptance testing of Orbital ATK motors at various test sites in the
United States, Japan, French Guiana, and China. We strongly recommend this support for
every flight program. We can provide trained personnel to monitor activities at the launch
site or in customer test facilities and to assist in resolution of problems.
Postflight Analysis. Analysis of flight data can help identify trends in motor performance
and thus eliminate potential problems. Further, evaluation during a program helps enhance
the predictability of flight performance. For example, comparison of ground data with other
flight data may enable the customer to reduce the weight of fuel for velocity trimming and
RCS, allowing for potential of enhanced spacecraft usable weight on subsequent launches.
Typical postflight analysis that Orbital ATK can support includes the following:
• Ballistic performance
• Acceleration profile
• Derived nonaxial (lateral) thrust data
• Motor temperatures
• Residual thrust
• Other (dependent on flight instrumentation)
Motor Data. A summary of STAR motor performance is presented in the following table.
The pages that follow contain data sheets for the various STAR motor configurations.
64
STAR Motor Performance and Experience Summary

Nominal Effective
Total Propellant Weight Propellant
STAR Model Diameter Specific
Impulse, Mass Tests Flights
Designation Number in. cm Impulse, lbm kg
lbf-sec Fraction
lbf-sec/lbm
3 TE-M-1082-1 3.18 8.08 281.4 266.0 1.06 0.48 0.42 26 3
3A TE-M-1089 3.18 8.08 64.4 241.2 0.27 0.12 0.14 2 3
4G TE-M-1061 4.45 11.30 595 269.4 2.16 0.98 0.65 2 0
5* TE-M-500 5.05 12.83 895 189.0 3.8 1.72 0.87 4 11
5A TE-M-863-1 5.13 13.02 1,289 250.8 5.05 2.27 0.49 6 3
5C/5CB TE-M-344-15 4.77 12.11 1,252 268 4.55 2.06 0.47 245 686
TE-M-344-16 4.77 12.11 1,249 262.0 4.62 2.10 0.47 20 160
5D TE-M-989-2 4.88 12.39 3,950 256.0 15.22 6.90 0.68 13 3
5F TE-M-1198 4.85 12.32 2,216 262.9 8.42 3.82 0.37 9 194
6 TE-M-541-3 6.2 15.75 3,077 287.0 10.7 4.85 0.80
47 238
6A* TE-M-542-3 6.2 15.75 2,063 285.3 7.2 3.27 0.72
6B TE-M-790-1 7.32 18.59 3,686 269.0 13.45 6.10 0.60 8 18
8 TE-M-1076-1 8.06 20.47 7,430 272.9 27.12 12.30 0.71 26 6
9 TE-M-956-2 9.0 22.86 9,212 289.1 31.8 14.42 0.78 1 0
10* TE-M-195 10.0 25.40 6,600 251.0 26.3 11.93 0.68 46 Classified
12* TE-M-236 12.0 30.48 10,350 252.0 40.3 18.28 0.66 160 349
12A* TE-M-236-3 12.1 30.73 13,745 270.0 50.2 22.77 0.67 6 Classified
12GV TE-M-951 12.24 31.58 20,669 282.4 72.6 32.9 0.79 5 2
13* TE-M-458 13.5 34.29 18,800 273.0 68.3 30.98 0.87 7 2
13A* TE-M-516 13.5 34.29 21,050 286.5 73.0 33.11 0.87 5 9
13B TE-M-763 13.57 34.47 26,050 285.0 90.9 41.23 0.88 1 2
13C* TE-M-345-11/12 13.5 34.29 18,200 218.0 66.5 30.16 0.80 125 131
13D* TE-M-375 13.5 34.29 17,200 223.0 63.0 28.58 0.81 10 2
13E* TE-M-385 12.7 32.26 14,200 211.0 55.4 25.13 0.82 65 48
13F* TE-M-444 13.5 34.29 21,190 240.0 73.5 33.34 0.83 5 9
15G TE-M-1030-1 15.04 38.2 50,210 281.8 175.5 79.61 0.85 11 10
17 TE-M-479 17.4 44.20 44,500 286.2 153.5 69.63 0.88 6 4
17A TE-M-521-5 17.4 44.20 71,800 286.7 247.5 112.26 0.89 10 7
20 Spherical* TE-M-251 20.0 50.80 66,600 234.0 253 114.76 0.93 1 1
20 TE-M-640-1 19.7 50.04 173,560 286.5 601.6 273.20 0.91 10 32
20A* TE-M-640-3 19.7 50.04 184,900 291.9 630.0 285.76 0.91 2 0
20B* TE-M-640-4 19.8 50.29 174,570 289.1 601.6 272.88 0.89 6 5
24 TE-M-604 24.5 62.23 126,000 282.9 440.6 199.85 0.92
24A* TE-M-604-2 24.5 62.23 112,400 282.4 393.8 178.62 0.92
24B* TE-M-604-3 24.5 62.23 126,230 282.9 441.4 200.22 0.92 9 6
24C TE-M-604-4 24.5 62.23 138,000 282.3 484.0 219.54 0.92
26 TE-M-442 26.0 66.04 138,500 271.0 508.5 230.65 0.86
4 14
26C TE-M-442-2 26.1 66.29 139,800 272.1 511.4 231.97 0.88
26B TE-M-442-1 26.1 66.29 142,760 271.7 524.0 237.68 0.91 1 8
65
Nominal Effective
Total Propellant Weight Propellant
STAR Model Diameter Specific
Impulse, Mass Tests Flights
Designation Number in. cm Impulse, lbm kg
lbf-sec Fraction
lbf-sec/lbm
27 TE-M-616 27.3 69.34 213,790 287.9 735.6 333.66 0.92 18 31
27H TE-M-1157 27.3 69.34 219,195 291.4 744.8 337.84 0.92 1 1
30* TE-M-700-2 30.0 76.20 300,940 293.0 1,021.7 463.44 0.94 4 0
30A* TE-M-700-4 30.0 76.20 302,350 294.7 1,021.0 463.12 0.94 1 0
30B* TE-M-700-5 30.0 76.20 328,200 293.0 1,113.0 504.85 0.94 14 29
30BP TE-M-700-20 30.0 76.20 328,455 292.3 1,113.6 505.12 0.93 5 23
30C TE-M-700-18 30.0 76.20 376,095 286.4 1,302.5 590.80 0.94 4 22
30C/BP TE-M-700-25 30.0 76.20 383,270 291.8 1,302.5 590.80 0.93 0 4
30E TE-M-700-19 30.0 76.20 407,550 290.4 1,392.0 631.40 0.93 3 11
31 TE-M-762 30.1 76.45 840,000 293.5 2,835.0 1285.94 0.93 6 17
37* TE-M-364-1 36.8 93.47 356,200 260.0 1,123.0 509.38 0.90 50 6
37B* TE-M-364-2 36.8 93.47 417,900 291.0 1,440.0 653.17 0.91 1 21
37C* TE-M-364-18 36.8 93.47 608,600 285.5 2,125.0 963.88 0.92 1 8
37D* TE-M-364-3 36.8 93.47 417,900 266.0 1,440.0 653.17 0.91 14 18
37E* TE-M-364-4 36.8 93.47 654,200 283.6 2,290.0 1038.73 0.93 13 75
37F* TE-M-364-19 36.8 93.47 549,536 286.0 1,909.3 866.04 0.93 8 10
37FM TE-M-1139 36.8 93.47 695,620 294.1 2,344.1 1063.27 0.93 5 30
37FMV TE-M-1139 36.8 93.47 685,970 289.8 2350.1 1065.99 0.93 0 0
37G* TE-M-364-11 36.8 93.47 671,809 289.9 2,348.0 1065.04 0.92 4 0
37GV TE-M-1007-1 35.2 89.41 634,760 293.5 2,148 974.3 0.92 1 0
37N* TE-M-364-14 36.8 93.47 357,500 290.0 1,232.0 558.83 0.90 1 8
37S* TE-M-364-15 36.8 93.47 420,329 287.3 1,449.5 657.48 0.92 2 24
37X* TE-M-714-1 36.8 93.47 685,148 295.6 2,350.7 1066.26 0.93 1 0
37XF* TE-M-714-6 36.7 93.22 571,470 290.0 1,950.4 884.69 0.93 9 9
37XFP TE-M-714- 36.7 93.22 570,040 290.0 1,948.2 883.69 0.92 3 41
16/17
37XFPV TE-M-988-1 36.7 93.22 570,040 290.0 1,948.2 883.69 0.91 1 0
37Y* TE-M-714-2 36.8 93.47 701,000 297.0 2,360.0 1070.48 0.93 2 0
40* TE-M-186-2 40.1 101.85 443,026 207.0 1,995.0 904.92 0.92 10 0
48*(short) TE-M-711-3 49.0 124.46 1,269,610 286.6 4,405.0 1998.08 0.95 18 29
48*(long) TE-M-711-8 49.0 124.46 1,296,300 292.9 4,405.0 1998.08 0.94
48A (short) TE-M-799-1 49.0 124.46 1,528,400 283.4 5,357.2 2429.99 0.94 1 0
48A (long) TE-M-799 49.0 124.46 1,563,760 289.9 5,357.2 2429.99 0.94
48B (short) TE-M-711-17 49.0 124.46 1,275,740 286.0 4,431.2 2009.96 0.94 3 104
48B (long) TE-M-711-18 49.0 124.46 1,303,700 292.1 4,431.2 2009.96 0.94
48BV TE-M-940-1 49.0 124.46 1,303,700 292.1 4,431.2 2009.96 0.94 3 2
48V TE-M-940-1 49.0 124.46 1,303,700 292.1 4,431.2 2009.96 0.93 3 1
63D TE-M-936 63.0 160.02 2,042,450 283.0 7,166.5 3250.67 0.93 5 3
63F TE-M-963-2 63.1 160.27 2,816,700 297.1 9,401.6 4264.50 0.93 4 2
75 TE-M-775-1 75.0 190.50 4,797,090 288.0 16,542 7503.32 0.93 1 0
92 – 93.0 236.22 10,120,100 287.7 34,879 15,820.85 0.94 0 0
*STAR motors that have been replaced by other motor configurations
66
STAR 3 TE-M-1082-1
MOTOR DIMENSIONS
Motor length, in................................................... 11.36
MOTOR PERFORMANCE (70°F VACUUM)

Burn time/action time, sec............................0.62/0.66
Ignition delay time, sec.........................................0.12
Burn time average chamber pressure, psia........1,502
Maximum chamber pressure, psia.....................1,596
Total impulse, lbf-sec..........................................281.4
Propellant specific impulse, lbf-sec/lbm..............266.0
Burn time average thrust, lbf.................................435
Maximum thrust, lbf...............................................461
NOZZLE
The STAR 3 motor was developed and qualified in 2003 as the
Initial throat diameter, in.....................................0.461
transverse impulse rocket system (TIRS) for the Mars Exploration Exit diameter, in..................................................2.072
Rover (MER) program for the Jet Propulsion Laboratory (JPL) in Expansion ratio, initial........................................20.2:1
Pasadena, CA. Three TIRS motors were carried on each of the
WEIGHTS, LBM.................................................
MER landers. One of the TIRS motors was fired in January 2004 to Total loaded..........................................................2.55
provide the impulse necessary to reduce lateral velocity of the MER Propellant ............................................................1.06
Spirit lander prior to landing on the Martian surface. The motor also Case assembly.....................................................0.40
has applicability for spin/despin and separation systems. Nozzle assembly .................................................0.58
Total inert..............................................................1.49
Burnout.................................................................1.49
Propellant mass fraction.......................................0.42
TEMPERATURE LIMITS
Operation................................................... -40º-104°F
Storage...................................................... -65º-140°F
PROPELLANT DESIGNATION.......... TP-H-3498
CASE MATERIAL ............................... TITANIUM

PRODUCTION STATUS
V0504007 [591]
................................................. FLIGHT-PROVEN
1800 1800
1600 1600
NOTE: Offload configuration delivering 171 lbf-sec
of total impulse also qualified
1400 1400
P
1200 1200
PRESSURE, PSIA
THRUST, L BF
1000 1000
800 800
F
600 600
400 400
200 200
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
0
TIME, SEC OSR No. 16-S-1432; 67
Dated 05 April 2016
STAR 3A TE-M-1089
MOTOR DIMENSIONS
Motor length, in.......................................................7.5

Ignition delay time, sec.......................................0.007
Burn time average chamber pressure, psia...........520
Maximum chamber pressure, psia........................676
Total impulse, lbf-sec............................................64.4
Effective specific impulse, lbf-sec/lbm ...............241.2
NOZZLE
Initial throat diameter, in.......................................0.46
Exit diameter, in......................................................1.1
The STAR 3A was developed Expansion ratio, initial..........................................5.7:1
and qualified in 2003 as an
WEIGHTS, LBM
offloaded and shortened
Total loaded..........................................................1.96
version of the STAR 3 used Propellant (including igniter).................................0.27
for JPL’s Mars Exploration Total inert..............................................................1.70
Rover (MER) transverse impulse rocket system (TIRS). It has a Burnout.................................................................1.70
shorter case and truncated exit cone to accommodate a lower Propellant mass fraction.......................................0.14
propellant weight and smaller available volume. The STAR 3A TEMPERATURE LIMITS
is ideally suited for separation, spin/despin, deorbit, and small Operation................................................... -40º-104°F
satellite applications. Storage...................................................... -65º-140°F
PROPELLANT DESIGNATION ......... TP-H-3498
180
V0604003 [593]
800
CASE MATERIAL ............................... TITANIUM
160 700
PRODUCTION STATUS
F ................................................. FLIGHT-PROVEN
140
600
PRESSURE, PSIA
120
500
THRUST, L BF
100
P 400
80
300
60
200
40
100
20
0 0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
TIME, SEC
OSR No. 16-S-1432; 68
Dated 05 April 2016
STAR 4G TE-M-1061
MOTOR DIMENSIONS
Motor length, in.....................................................5.43

Total impulse, lbf-sec.............................................595
Burn time average thrust, lbf...................................58
Maximum thrust, lbf.................................................69
NOZZLE
This STAR motor was developed and tested in January 2000 under Exit diameter, in....................................................1.13
Expansion ratio, initial........................................56.8:1
a NASA Goddard Space Flight Center program for a low-cost, high
mass fraction orbit adjust motor for use in deploying constellations WEIGHTS, LBM
of very small satellites (nanosatellites). The first static test of the Total loaded..........................................................3.30
Propellant ............................................................2.16
STAR 4G prototype motor was conducted 8 months after program
Heavyweight Nano ESA.......................................0.17
start. The motor is designed to operate at high chamber pressure
Case assembly.....................................................0.49
and incorporates a noneroding throat insert to maximize specific Nozzle assembly .................................................0.46
impulse. Total inert..............................................................1.12
Burnout.................................................................1.07
TEMPERATURE LIMITS
Operation...................................................... 40º-90°F
Storage....................................................... 40º-100°F
PROPELLANT DESIGNATION.......... TP-H-3399
CASE MATERIAL
80
V0301055A [482]
3000 .......................... GRAPHITE-EPOXY COMPOSITE

P
70 PRODUCTION STATUS............. DEVELOPMENT
2500
60
F 2000
Vacuum Thrust, lbf
50
Pressure, psia
40 1500
30
1000
20
500
10
0
0 2 4 6 8 10 12
0
Time, sec OSR No. 16-S-1432; 69
Dated 05 April 2016
STAR 5A TE-M-863-1
MOTOR DIMENSIONS
Motor length, in.....................................................8.84

Total impulse, lbf-sec..........................................1,289
Burn time average thrust, lbf...................................38
Maximum thrust, lbf.................................................38
NOZZLE
Exit diameter, in..................................................1.284
The STAR 5A rocket motor was qualified in 1988 to provide a Expansion ratio, initial........................................28.6:1
minimum acceleration and extended burn delta-V impulse. With a
WEIGHTS, LBM
low-average thrust and a unique off-center nozzle design, the motor Total loaded........................................................10.24
can be utilized in many nonstandard geometric configurations for Propellant ............................................................5.05
small payload placement or spin-up applications. The STAR 5A Case assembly.....................................................2.02
first flew in 1989 from the Space Shuttle. Nozzle assembly .................................................0.57
Total inert..............................................................5.17
Burnout.................................................................5.08
TEMPERATURE LIMITS
Operation..................................................... -4º-104°F
Storage...................................................... -76º-140°F
SPIN EXPERIENCE, RPM..................UP TO 60
PROPELLANT DESIGNATION ........TP-H-3399
CASE MATERIAL............................ ALUMINUM
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 70
Dated 05 April 2016
STAR 5C TE-M-344-15
MOTOR DIMENSIONS
Motor length, in...................................................13.43

The STAR 5C rocket motor was initially designed, developed,
qualified, and placed in production (1960 through 1963) under a
contract with Martin Marietta. The STAR 5C is used to separate NOZZLE
the second stage from the trans-stage on the Titan II missile and Initial throat diameter, in.....................................0.483
Exit diameter, in....................................................2.34
Titan launch vehicle. The current version was qualified for use in
1976, replacing the earlier main propellant grain with TP-H-3062.
WEIGHTS, LBM
Total loaded..........................................................9.86
Propellant (including igniter propellant)................4.55
Case assembly.....................................................4.24
Nozzle assembly .................................................0.40
Total inert .............................................................5.28
Burnout.................................................................5.16
TEMPERATURE LIMITS
Operation.................................................... 20º-130°F
Storage...................................................... -25º-130°F
CASE MATERIAL........................... 4130 STEEL

PRODUCTION STATUS........ FLIGHT-PROVEN

OSR No. 16-S-1432; 71
Dated 05 April 2016
STAR 5CB TE-M-344-16
MOTOR DIMENSIONS
Motor length, in...................................................13.43

Propellant specific impulse, lbf-sec/lbm.................270
Effective specific impulse, lbf-sec/lbm...................262
The STAR 5CB rocket motor was redesigned and requalified to Maximum thrust, lbf...............................................492
separate the second stage from the upper stage on the Titan IV
NOZZLE
launch vehicle. The motor incorporates a reduced aluminum Initial throat diameter, in.....................................0.483
content (2% Al) propellant to minimize spacecraft contamination Exit diameter, in....................................................2.34
during firing. The case, nozzle, and igniter components are Expansion ratio, initial........................................23.5:1
unchanged from the STAR 5C design, but the motor has been WEIGHTS, LBM
qualified (in 1989) for the more severe Titan IV environments. This Total loaded..........................................................9.93
motor was first flown in 1990. Propellant (excluding 0.03 lbm igniter propellant).4.62
Case assembly.....................................................4.24
The STAR 5CB has been adapted for other applications.
Nozzle assembly .................................................0.40
Mounting lugs and studs can be added to the head-end closure
Total inert .............................................................5.28
while removing the skirts on either end to accommodate mission- Burnout.................................................................5.16
specific attachment features. Propellant mass fraction.......................................0.47
TEMPERATURE LIMITS
Operation...................................................... 0º-130°F
Storage...................................................... -35º-172°F
PROPELLANT DESIGNATION.......TP-H-3237A
CASE MATERIAL........................... 4130 STEEL


OSR No. 16-S-1432; 72
Dated 05 April 2016
STAR 5D TE-M-989-2
MOTOR DIMENSIONS
Motor length, in.....................................................32.7
MOTOR PERFORMANCE (-22°F VACUUM)

Burn time average thrust, lbf...............................1251
Maximum thrust, lbf............................................1,410
NOZZLE
Exit diameter, in..................................................2.345
Expansion ratio, initial..........................................7.3:1
Cant angle, deg.......................................................17
The STAR 5D rocket motor was designed and qualified (1996)
to serve as the rocket-assisted deceleration (RAD) motor on the WEIGHTS, LBM
Mars Pathfinder mission for the Jet Propulsion Laboratory (JPL) Total loaded........................................................22.55
in Pasadena, CA. The STAR 5D features a titanium case, head- Propellant (including igniter propellant)..............15.22
Case assembly.....................................................5.93
end ignition system, and canted nozzle design and is based on
Nozzle assembly .................................................1.40
earlier STAR 5 designs. Three of these motors were fired on July Total inert .............................................................7.33
4, 1997, to slow the Pathfinder spacecraft to near-zero velocity Burnout.................................................................7.12
before bouncing on the surface of Mars. Propellant mass fraction.......................................0.68
TEMPERATURE LIMITS
Operation................................................... -67º-158°F
Storage...................................................... -80º-172°F
1600
V0703011 [567]
1600
1400 1400 CASE MATERIAL...............................TITANIUM

P
1200 1200 PRODUCTION STATUS

.............................................. FLIGHT-PROVEN
PRESSURE, PSI
1000 1000
THRUST, LBf
F
800 800
600 600
400 400
200 200
0 0
0 0.5 1 1.5 2 2.5 3 3.5
TIME, SEC Approved for Public Release

OSR No. 16-S-1432; 73
Dated 05 April 2016
STAR 5F TE-M-1198
MOTOR DIMENSIONS
Motor length, in...................................................37.26

Burn time average thrust, lbf*.............................1,188
The STAR 5F rocket motor was designed as the Atlas V launch
Maximum thrust, lbf*...........................................1,363
vehicle first stage retro motor for use during first and second stage *Along nozzle centerline
separation. It incorporates numerous design features from the
STAR 5CB, STAR 5D, and STAR 5E designs to maximize heritage NOZZLE
and drive high reliability. The STAR 5F features a stainless steel Initial throat diameter, in.......................................0.85
Exit diameter, in....................................................2.55
case, closures, and exit cone; a head-end ignition system; a
Expansion ratio, initial..........................................9.1:1
severely canted nozzle design; and reduced aluminum content Cant angle, deg....................................................20.0
propellant to minimize spacecraft contamination during firing. The
motor has been qualified for the severe Atlas V environments, WEIGHTS, lbm
Total loaded........................................................30.95
including nine static tests in 2011 and 2012.
Propellant ............................................................8.42
Total inert ...........................................................22.53
TEMPERATURE LIMITS
Operation.................................................... 14º-124°F
Storage...................................................... -35º-160°F
PROPELLANT DESIGNATION ..... TP-H-3237B

1,600 1,800
CASE MATERIAL................STAINLESS STEEL
1,400 1,600
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN
1,400
1,200
F P
1,200
1,000
VACUUM THRUST, lbf
PRESSURE, PSIA
1,000
800
800
600
600
400
400
200 200
0 0
0.0 0.5 1.0 1.5 2.0 2.5 Approved for Public Release
Dated 05 April 2016
STAR 6B TE-M-790-1
MOTOR DIMENSIONS
Motor length, in...................................................15.89

Burn time/action time, sec................................5.9/7.2
Propellant specific impulse, lbf-sec/lbm.................274
Effective specific impulse, lbf-sec/lbm...................269
The STAR 6B rocket motor was developed for spin-up and Maximum thrust, lbf...............................................634
axial propulsion applications for re-entry vehicles. The design
NOZZLE
incorporates an aluminum case and a carbon-phenolic nozzle Initial throat diameter, in.....................................0.662
assembly. The STAR 6B was qualified in 1984 and first flew in Exit diameter, in....................................................3.76
1985. The motor is capable of spinning at 16 revolutions per Expansion ratio, initial/average.....................32:1/28:1
second during firing and is qualified for propellant loadings from
WEIGHTS, LBM
5.7 to 15.7 lbm.
Total loaded........................................................22.62
Propellant (including igniter propellant)..............13.45
Case and closure assembly.................................6.02
Nozzle assembly .................................................0.80
Total inert..............................................................9.17
Burnout.................................................................8.92
TEMPERATURE LIMITS
Operation.....................................................30º-110°F
Storage...................................................... -20º-160°F
SPIN EXPERIENCE, RPM........................... 960
PROPELLANT DESIGNATION.......TP-H-3237A
CASE MATERIAL............................ ALUMINUM
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 75
Dated 05 April 2016
STAR 8 TE-M-1076-1
MOTOR DIMENSIONS
Motor length, in...................................................27.07
MOTOR PERFORMANCE (-22°F vacuum)

The STAR 8 was developed and qualified (2002) as the rocket Effective specific impulse, lbf-sec/lbm................272.9
assisted deceleration (RAD) motor for the Mars Exploration Burn time average thrust, lbf..............................1,681
Rover (MER) program for the Jet Propulsion Laboratory (JPL) Maximum thrust, lbf............................................1,742
in Pasadena, CA. The motor is based on the STAR 5D motor
NOZZLE
technology developed for JPL’s Mars Pathfinder program. The Initial throat diameter, in.....................................0.879
STAR 8 first flew in January 2004 when three motors were used to Exit diameter, in..................................................4.095
decelerate each of the Spirit and Opportunity rovers for landing at Expansion ratio, initial........................................21.7:1
Gusev Crater and Meridiani Planum on Mars. Cant angle, deg.......................................................17
WEIGHTS, LBM
Total loaded........................................................38.43
Propellant ..........................................................27.12
Case assembly.....................................................6.12
Nozzle assembly .................................................3.69
Total inert............................................................ 11.31
Burnout............................................................... 11.20
TEMPERATURE LIMITS
Operation................................................... -40º-104°F
Storage...................................................... -65º-140°F
CASE MATERIAL...............................TITANIUM
V0504006 [591]
1800 1800
F
1600
PRODUCTION STATUS
1600
.............................................. FLIGHT-PROVEN
1400 1400
P
1200 1200
PRESSURE, PSIA
THRUST, LBF
1000 1000
800 800
600 600
400 400
200 200
0 0
0.0 1.0 2.0 3.0 4.0 5.0 Approved for Public Release
Dated 05 April 2016
STAR 9 TE-M-956-2
MOTOR DIMENSIONS
Motor diameter, in...................................................9.0
Motor length, in...................................................19.96
MOTOR PERFORMANCE (70°F vacuum)

Burn time/action time, sec................................9.4/9.8
Maximum thrust, lbf............................................ 1,311
NOZZLE
Exit diameter, in....................................................6.52
Expansion ratio, initial...........................................73:1
WEIGHTS, LBM
Total loaded..........................................................41.0
Propellant (including igniter propellant)................31.8
Case assembly (including igniter inerts).................6.5
Nozzle assembly ...................................................2.7
The STAR 9 rocket motor was developed in 1993 on independent Total inert ...............................................................9.2
research and development (IR&D) funds to demonstrate a number Burnout...................................................................9.1
of low-cost motor technologies. These included an integral aft Propellant mass fraction.......................................0.78
polar boss/exit cone, two-dimensional carbon-carbon throat, and TEMPERATURE LIMITS
case-on-propellant manufacturing technique. Operation...................................................... 40º-90°F
Storage......................................................... 30º-95°F

1600 1600 CASE MATERIAL
.....................GRAPHITE-EPOXY COMPOSITE
P
1200 1200 PRODUCTION STATUS...... DEMONSTRATION

PRESSURE, PSIA
THRUST, LBF
F
800 800
400 400
0 0
0 2 4 6 8 10 12

OSR No. 16-S-1432; 77
Dated 05 April 2016
STAR 12GV TE-M-951
MOTOR DIMENSIONS
Motor length, in.....................................................22.5

Total impulse, lbf-sec........................................20,669
NOZZLE
The STAR 12GV rocket motor served as the third stage of the U.S. Exit diameter, in....................................................5.26
Navy/MDA Terrier Lightweight Exoatmospheric Projectile (LEAP) Expansion ratio, initial...........................................58:1
TVC angle, deg............................................... ± 5 deg
experiments. The motor first flew in March 1995. The stage has
TVC capability, head-end flight destruct ordnance, and utilizes a WEIGHTS*, LBM
graphite-epoxy composite case. It is compatible with an aft-end Total loaded..........................................................92.5
attitude control system (ACS) module. Orbital ATK developed the Propellant ............................................................72.6
motor design and component technology between 1992 and 1995 Case assembly.....................................................14.3
Nozzle assembly ...................................................4.5
under the Advanced Solid Axial Stage (ASAS) program.
Total inert .............................................................19.8
Burnout.................................................................19.2
TEMPERATURE LIMITS
Operation...................................................... 40º-95°F
Storage......................................................... 0º-130°F
V0802006 [532]
3,000 3,000
2,500 2,500
........................................................TP-H-3340A
F
P CASE MATERIAL
2,000 2,000
PRESSURE, PSIA
THRUST, lbf
1,500 1,500
PRODUCTION STATUS
1,000 1,000
.............................................. FLIGHT-PROVEN
*Includes actuators and cables only. Battery and
controller weights and ACS are not included
500 500
0 0
0 2 4 6 8 10 12 14 16 18

OSR No. 16-S-1432; 78
Dated 05 April 2016
STAR 13B TE-M-763
MOTOR DIMENSIONS
Motor length, in................................................... 25.11

NOZZLE
The STAR 13B incorporates a titanium case developed for the Exit diameter, in....................................................8.02
STAR 13 with the propellant and nozzle design of an earlier Expansion ratio, initial/average...............49.8:1/41.0:1
STAR 13 apogee motor. The motor design was qualified in 1983
WEIGHTS, LBM
and was used in 1984 to adjust orbit inclinations of the Active
Total loaded........................................................103.7
Magnetosphere Particle Tracer Experiment (AMPTE) satellite Propellant.............................................................90.9
launched from Delta 180 and in 1988 as a kick motor for a missile Case assembly.......................................................5.6
defense experiment. Nozzle assembly ...................................................3.7
Total inert..............................................................12.8
Burnout.................................................................12.3
TEMPERATURE LIMITS
Operation.....................................................40º-110°F
Storage........................................................40º-110°F
PROPELLANT DESIGNATION.........TP-H-3062
CASE MATERIAL ..............................TITANIUM
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 79
Dated 05 April 2016
STAR 15G TE-M-1030-1
MOTOR DIMENSIONS
Motor length, in...................................................31.57

Burn time average thrust, lbf..............................1 , 4 7 0
NOZZLE
Exit diameter, in....................................................8.12
AN UPPER-STAGE MOTOR
The STAR 15G rocket motor was designed and qualified during
1997 in two different grain design configurations. The motor design WEIGHTS, LBM
was based on the ASAS 15-in. diameter development motor (DM) Total loaded (excluding ETA and S&A)...............206.6
Propellant (excluding 0.12 lbm of igniter
that was used to evaluate design features and component and
propellant)...........................................................175.5
material technology in seven tests between December 1988 and Case assembly.....................................................22.6
June 1991. Orbital ATK employed its Thiokol Composite Resin Nozzle assembly ...................................................4.6
(TCR) technology on this motor, one of several STAR designs to Total inert..............................................................30.9
use a wound graphite-epoxy composite case. Burnout.................................................................28.3
The motor’s unique regressive thrust-time profile is an example
of propellant grain tailoring to restrict thrust to maintain a low level TEMPERATURE LIMITS
Operation.....................................................40º-110°F
of acceleration to the payload. An alternative propellant loading of
Storage........................................................40º-110°F
131 lbm was also tested during qualification.
V1101041 [507]
4,000 2,500
CASE MATERIAL
P
F
2,000
3,000
PRODUCTION STATUS
VACUUM THRUST, lbf
PRESSURE, PSIA
1,500 .............................................. FLIGHT-PROVEN

2,000
1,000
1,000
500
0 0 Approved for Public Release

0 5 10 15 20 25 30 35 40 45 50 OSR No. 16-S-1432; 80
TIME, SEC
Dated 05 April 2016
STAR 17 TE-M-479
MOTOR DIMENSIONS
Motor length, in...................................................27.06

NOZZLE
Exit diameter, in..................................................10.69
The STAR 17 motor has served as the apogee kick motor (AKM) Expansion ratio, initial........................................60.7:1
for several programs. The STAR 17 features a silica-phenolic exit
WEIGHTS, LBM
cone and a titanium case with a mounting ring on the aft end that
Total loaded........................................................174.3
can be relocated as required by the customer.
Propellant...........................................................153.5
The STAR 17 motor was developed and qualified in six tests Case assembly.......................................................8.8
conducted at Orbital ATK and Arnold Engineering Development Nozzle assembly ...................................................7.0
Center (AEDC) through March 1967. The initial STAR 17 flight Total inert..............................................................20.8
was on Delta 57 in July 1968 from the Western Test Range Burnout.................................................................18.8
(WTR). Subsequent launches have been conducted from Eastern
Test Range (ETR) on Delta and the Atlas vehicle from WTR. TEMPERATURE LIMITS
Operation...................................................... 0º-120°F
Storage......................................................... 0º-120°F
SPIN EXPERIENCE, RPM .......................... 100
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 81
Dated 05 April 2016
STAR 17A TE-M-521-5
MOTOR DIMENSIONS
Motor diameter, in............................................... 17.4*
Motor length, in...................................................38.64

The STAR 17A motor is an apogee kick motor (AKM) used for the NOZZLE
interplanetary monitoring platform (IMP) and other small satellites. Initial throat diameter, in.....................................1.884
The motor utilizes an extended titanium case to increase total Exit diameter, in..................................................13.75
impulse from the STAR 17 and has been used for various missions Expansion ratio, initial........................................53.2:1
in launches from Delta and Atlas vehicles between 1969 and
WEIGHTS, LBM
1977. The STAR 17A motor was qualified in the -5 configuration Total loaded...........................................................277
for IMP H and J. Propellant...........................................................247.5
Case assembly.....................................................13.1
Nozzle assembly .................................................10.3
Total inert..............................................................29.5
Burnout.................................................................26.5
TEMPERATURE LIMITS
Operation.......................................................0º-110°F
Storage..........................................................0º-110°F
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN
*The diameter extends to 18.38 in. at the location of the

attachment flange

OSR No. 16-S-1432; 82
Dated 05 April 2016
STAR 20 TE-M-640-1
MOTOR DIMENSIONS
Motor length, in.....................................................58.5

Total impulse, lbf-sec......................................173,560
The STAR 20 Altair III rocket motor was developed as the
propulsion unit for the fourth stage of the Scout launch vehicle. The
filament-wound, fiberglass-epoxy case contains a 16% aluminum
carboxyl-terminated polybutadiene (CTPB) propellant grain. The NOZZLE
Initial throat diameter, in.........................................2.3
lightweight, external nozzle is a composite of graphite and plastic
Exit diameter, in....................................................16.5
that is backed by steel. The STAR 20 Altair III was developed in Expansion ratio, initial........................................50.2:1
testing between 1972 and 1978 with flights from the Western Test
WEIGHTS, LBM
Range (WTR), San Marcos, and Wallops Flight Facility beginning
Total loaded........................................................662.3
with Scout 189 in August 1974. Propellant (including igniter propellant)..............601.6
Orbital ATK also developed a modified version of the STAR 20. Case assembly.....................................................24.3
The STAR 20B design increased case structural capability over Nozzle assembly .................................................12.5
the standard STAR 20 to support launch from an F-15 aircraft for Total inert..............................................................60.7
Burnout.................................................................58.6
the Antisatellite Weapons (ASAT) program. The STAR 20B ASAT
motor was qualified during testing in 1982 to 1983 to support flights
between January 1984 and September 1986. TEMPERATURE LIMITS
Operation.................................................... 40º-100°F
Storage........................................................30º-110°F

V0604006 [593]
120.0 120.0
100.0 100.0
CASE MATERIAL ......... FIBER GLASS-EPOXY
COMPOSITE
P
80.0 80.0 PRODUCTION STATUS........ FLIGHT-PROVEN
PRESSURE, PSIA
THRUST, LBF
60.0 60.0
F
40.0 40.0
20.0 20.0
0.0 0.0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 Approved for Public Release
TIME,SEC OSR No. 16-S-1432; 83
Dated 05 April 2016
STAR 24 TE-M-640
MOTOR DIMENSIONS
Motor length, in.....................................................40.5

NOZZLE
The STAR 24 rocket motor was qualified in 1973 and flown as Exit diameter, in..................................................14.88
the apogee kick motor (AKM) for the Skynet II satellite. The motor Expansion ratio, initial/average...............37.8:1/36.7:1
assembly uses a titanium case and carbon-phenolic exit cone.
WEIGHTS, LBM
Different versions of this motor have been qualified for the Pioneer
Total loaded........................................................481.0
Venus mission (1978). The initial STAR 24 flight was in 1974 on Propellant (including igniter propellant)..............440.6
Delta 100. The STAR 24 motor has flown from both the Eastern Case ....................................................................13.0
Test Range (ETR) and Western Test Range (WTR). Nozzle assembly .................................................13.1
Total inert..............................................................40.4
Burnout.................................................................35.6
TEMPERATURE LIMITS
Operation.......................................................0º-110°F
Storage........................................................20º-110°F

OSR No. 16-S-1432; 84
Dated 05 April 2016
STAR 24C TE-M-640-4
MOTOR DIMENSIONS
Motor length, in.....................................................42.0

The STAR 24C was designed and qualified (in 1976) for launch
NOZZLE
of NASA’s International Ultraviolet Experiment (IUE) satellite in
January 1978 from the Eastern Test Range (ETR) on Delta 138. It Exit diameter, in..................................................14.88
operates at a slightly higher chamber pressure than earlier STAR Expansion ratio, initial........................................37.1:1
24 motors. The STAR 24C has an elongated cylindrical section
and a larger nozzle throat to accommodate increased propellant WEIGHTS, LBM
Total loaded........................................................527.5
loading.
Propellant (including 1.2 lbm igniter propellant)
...........................................................................484.0
Case ....................................................................14.1
Nozzle assembly .................................................13.1
Total inert..............................................................43.5
Burnout.................................................................38.7
TEMPERATURE LIMITS
Operation......................................................0º-110°F\
6000
V0703012 [567]
Storage........................................................20º-110°F
600
P
5000 500
4000 400 CASE MATERIAL...............................TITANIUM
PRESSURE, PSI
THRUST, LBf
F
PRODUCTION STATUS
3000 300 .............................................. FLIGHT-PROVEN
2000 200
1000 100
0 0
0 5 10 15 20 25 30 35
OSR No. 16-S-1432; 85
Dated 05 April 2016
STAR 26 TE-M-442
MOTOR DIMENSIONS
Motor length, in.....................................................33.0

NOZZLE
Exit diameter, in..................................................12.50
WEIGHTS, LBM
The STAR 26 was qualified in 1964 for flight as an upper stage Total loaded........................................................594.0
in the Sandia National Laboratories’ Strypi IV vehicle. Similar in Propellant (including 1.2 lbm igniter propellant)
design to its predecessor, the STAR 24, this motor offers a higher ...........................................................................508.5
Case assembly.....................................................39.6
thrust.
Nozzle assembly .................................................23.3
Total inert .............................................................85.5
Burnout.................................................................83.0
TEMPERATURE LIMITS
Operation...................................................... 50º-90°F
Storage....................................................... 40º-120°F
PROPELLANT DESIGNATION......... TP-H-3114
CASE MATERIAL......................... D6AC STEEL
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 86
Dated 05 April 2016
STAR 26B TE-M-442-1
MOTOR DIMENSIONS
Motor length, in.....................................................33.1

Isp based on Burner IIA flight data)..........................
NOZZLE
Exit diameter, in..................................................12.50
The STAR 26B is a version of the STAR 26 that is lightened by
utilizing a titanium case. This weight savings has allowed increased WEIGHTS, LBM
propellant loading, resulting in extended performance. The STAR Total loaded........................................................575.6
26B was qualified in a 1970 test and was flown as an upper stage
...........................................................................524.0
on the Burner IIA spacecraft for Boeing and the U. S. Air Force Case assembly.....................................................23.5
beginning in 1972. Nozzle assembly .................................................19.3
Total inert..............................................................51.6
Burnout.................................................................50.3
TEMPERATURE LIMITS
Operation...................................................... 50º-90°F
Storage....................................................... 40º-100°F
PROPELLANT DESIGNATION ........ TP-H-3114
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 87
Dated 05 April 2016
STAR 26C TE-M-442-2
MOTOR DIMENSIONS
Motor length, in.....................................................33.1

NOZZLE
Exit diameter, in..................................................12.50
The STAR 26C employs the same titanium alloy case as the STAR
WEIGHTS, LBM
26B; however, the insulation is increased to accommodate high- Total loaded........................................................579.0
spin-rate applications. The motor has been used as an upper Propellant (including igniter propellant).............. 511.4
stage for Sandia National Laboratories’ Strypi IV vehicle and for Case assembly.....................................................23.6
applications for the U.S. Army. Nozzle assembly .................................................19.8
Total inert..............................................................67.6
Burnout.................................................................65.1
TEMPERATURE LIMITS
Operation...................................................... 50º-90°F
Storage....................................................... 40º-100°F
SPIN CAPABILITY, RPM.............................. 250
PROPELLANT DESIGNATION ........ TP-H-3114

OSR No. 16-S-1432; 88
Dated 05 April 2016
STAR 27 TE-M-616
MOTOR DIMENSIONS
Motor length, in.....................................................48.7
MOTOR PERFORMANCE (60°F VACUUM)*

NOZZLE
The STAR 27 rocket motor was developed and qualified in Initial throat diameter, in.......................................2.74
1975 for use as the apogee kick motor (AKM) for the Canadian Exit diameter, in....................................................19.1
Communications Research Centre’s Communications Technology Expansion ratio, initial........................................48.8:1
Satellite. With its ability to accommodate various propellant
WEIGHTS, LBM
loadings (9% offload flown) and explosive transfer assemblies, Total loaded........................................................796.2
it has served as the AKM for various applications. The high- Propellant (including 0.5 lbm igniter propellant)
performance motor utilizes a titanium case and carbon-phenolic ...........................................................................735.6
Case assembly.....................................................23.6
nozzle. The motor first flew in January 1976 on Delta 119. It has
Nozzle assembly..................................................20.4
flown for Navigation Satellite Timing and Ranging (NAVSTAR)
Total inert..............................................................60.6
on Atlas vehicles launched from the Western Test Range (WTR), Burnout.................................................................53.6
for Geosynchronous Orbiting Environmental Satellites (GOES), Propellant mass fraction.......................................0.92
for the Japanese N-II vehicle from Tanagashima, and for the
TEMPERATURE LIMITS
Geostationary Meteorological Satellite (GMS) series of weather Operation..................................................20 to 100°F
satellites. Storage.....................................................40 to 100°F
V0604007 [593]
SPIN CAPABILITY, RPM...............................110
8,000 700
P PROPELLANT DESIGNATION ........TP-H-3135
7,000
600
6,000
500
5,000
PRESSURE, PSIA
THRUST, LBF
F 400
4,000
300
3,000
200
2,000
100
1,000
0 0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 OSR No. 16-S-1432; 89
TIME,SEC Dated 05 April 2016
STAR 27H TE-M-1157
MOTOR DIMENSIONS
Motor length, in.....................................................48.0
MOTOR PERFORMANCE (70°F VACUUM)*

The STAR 27H was developed as the apogee kick motor (AKM) NOZZLE
for NASA’s Interstellar Boundary Explorer (IBEX) mission in 2006 Initial throat diameter, in.......................................2.20
Exit diameter, in..................................................19.89
and completed qualification testing in July 2007. The STAR 27H is
an updated version of the previously qualified STAR 27 motor and
features a titanium case with forward and meridional attach flanges WEIGHTS, LBM
and Orbital ATK’s space-qualified HTPB propellant. The nozzle Total loaded........................................................810.9
design, which is also used on the STAR 30C motor, incorporates Propellant (including 0.5 lbm igniter propellant
a contoured nozzle with an integral toroidal igniter and carbon- ...........................................................................744.8
Case assembly.....................................................21.8
phenolic exit cone and has flown on over 20 successful missions.
Nozzle assembly..................................................29.0
Total inert..............................................................66.1
Burnout.................................................................58.8
TEMPERATURE LIMITS
Operation....................................................40 to 90°F
Storage...................................................40 TO 100°F
7000 700
SPIN CAPABILITY, RPM...............................110
P PROPELLANT DESIGNATION ........TP-H-3340
6000 600
5000 500
F
PRESSURE, psia
THRUST, lbf
4000 400
3000 300
2000 200
1000 100
0 0
0 5 10 15 20 25 30 35 40 45 50 Approved for Public Release
TIME, sec OSR No. 16-S-1432; 90
Dated 05 April 2016
STAR 30 SERIES
91
STAR 30BP TE-M-700-20
MOTOR DIMENSIONS
Motor length, in.....................................................59.3

Burn time/action time, sec..................................54/55
The STAR 30BP rocket motor serves as the apogee kick motor Maximum average thrust, lbf..............................6,945
(AKM) for several different satellite manufacturers such as RCA/
NOZZLE
GE/Lockheed Martin, Hughes/Boeing, and Orbital. The design
incorporates an 89%-solids hydroxyl-terminated polybutadiene Exit diameter, in....................................................23.0
(HTPB) propellant in a 6Al-4V titanium case insulated with silica- Expansion ratio, initial........................................73.7:1
filled ethylene propylene diene monomer (EPDM) rubber. This
motor was the prototype for a head-end web grain design with an WEIGHTS, LBM
Total loaded*....................................................1,196.7
integral toroidal igniter incorporated into the submerged nozzle.
The STAR 30BP was qualified in 1984 and has flown from Ariane, ........................................................................ 1,113.6
Space Shuttle, and Delta. Case assembly.....................................................30.5
Nozzle/igniter assembly
(excluding igniter propellant)................................33.8
Total inert*.............................................................83.1
Burnout*................................................................72.4
Propellant mass fraction*............................. 0.93*
Excluding remote S&A/ETA
TEMPERATURE LIMITS
Operation...................................................... 40º-90°F
V1101034 [507]
Storage....................................................... 40º-100°F
10,000 800
700
8,000
F P 600
VACUUM THRUST, lbf
PRESSURE, PSIA
500
6,000
400 PRODUCTION STATUS

4,000 300
.............................................. FLIGHT-PROVEN
Note: Design has been ground tested with a 20%
200 offload
2,000
100
0 0
0 10 20 30 40 50 60 70
OSR No. 16-S-1432; 92
Dated 05 April 2016
STAR 30C TE-M-700-18
MOTOR DIMENSIONS
Motor length, in.....................................................58.8

The STAR 30C was qualified in 1985 as an apogee kick motor NOZZLE
(AKM) for the RCA/GE/Lockheed Martin Series 3000 satellites. It Initial throat diameter, in.......................................2.89
currently serves on the Hughes/Boeing Satellite Systems HS-376 Exit diameter, in....................................................19.7
spacecraft. The case design incorporates an elongated cylindrical Expansion ratio, initial........................................46.4:1
section, making the case 5 inches longer than the STAR 30BP
WEIGHTS, LBM
case. Like the STAR 30BP, the STAR 30C uses an 89%-solids Total loaded*....................................................1,389.3
HTPB propellant in a 6Al-4V titanium case insulated with silica-filled Propellant (including igniter propellant)
EPDM rubber. It has a contoured nozzle with an integral toroidal ........................................................................1,302.5
igniter and a carbon-phenolic exit cone. However, the nozzle is Case assembly.....................................................35.7
truncated 5 inches to maintain nearly the same overall length as the (excluding igniter propellant).......................................
STAR 30BP. The STAR 30C has flown since 1985 from the Space Total inert*.............................................................84.8
Shuttle, Ariane, Long March, and Delta. Burnout*................................................................74.2
Propellant mass fraction*......................................0.94
*Excluding remote S&A/ETA
TEMPERATURE LIMITS
Operation...................................................... 40º-90°F
Storage....................................................... 40º-100°F

V1101035 [507]
12,000 800
10,000
700
P
F 600
VACUUM THRUST, lbf
8,000
PRESSURE, PSIA
500
6,000 400
300
4,000
200
2,000
100
0 0
0 10 20 30 40 50 60 Approved for Public Release
Dated 05 April 2016
STAR 30C/BP TE-M-700-25
MOTOR DIMENSIONS
Motor length, in.....................................................64.3

The STAR 30C/BP rocket motor combines the flight-qualified STAR Burn time average thrust, lbf..............................7,400
30C motor case with the same flight-qualified nozzle assembly as Maximum thrust, lbf............................................8,550
the STAR 30BP and STAR 30E motors. No ground qualification
test was performed before the first flight. This combination NOZZLE
increases the overall motor length and improves the delivered Isp.
Exit diameter, in....................................................23.0
The STAR 30C/BP has flown on the Hughes/BSS HS-376 and Expansion ratio, initial/average..........................63.2:1
Orbital Sciences Start-1 Bus satellites. The design incorporates an
89%-solids HTPB propellant in a 6Al-4V titanium case insulated WEIGHTS, LBM
Total loaded*....................................................1,393.6
with silica-filled EPDM rubber. It has a contoured nozzle with an
Propellant (including 0.6 lbm igniter propellant)..........
integral toroidal igniter and a carbon-phenolic exit cone. ........................................................................1,302.5
Case assembly.....................................................35.7
(including igniter propellant).................................34.5
Total inert*.............................................................90.6
Burnout*................................................................79.6
TEMPERATURE LIMITS
Operation...................................................... 40º-90°F
12,000
V1101006 [507]
800 Storage....................................................... 40º-100°F
700 SPIN EXPERIENCE, RPM........................... 100

10,000
P
F 600
VACUUM THRUST, lbf
8,000
PRESSURE, PSIA
500
6,000 400
300
4,000
200
2,000
100
0 0
0 10 20 30 40 50 60
OSR No. 16-S-1432; 94
Dated 05 April 2016
STAR 30E TE-M-700-19
MOTOR DIMENSIONS
Motor length, in.....................................................66.3

The STAR 30E serves as an apogee kick motor (AKM). Qualified in Burn time average thrust, lbf..............................7,900
December 1985, the design incorporates a case cylinder that is 7 Maximum thrust, lbf............................................8,850
inches longer than the STAR 30BP and a nozzle assembly with the
NOZZLE
same length exit cone as the STAR 30BP. It utilizes an 89%-solids
HTPB propellant in a 6Al-4V titanium case insulated with silica-filled Exit diameter, in....................................................23.0
EPDM rubber. It has a contoured nozzle with an integral toroidal Expansion ratio, initial........................................58.6:1
igniter and a carbon-phenolic exit cone. The STAR 30E first flew as
an AKM for Skynet in a December 1988 launch from Ariane. WEIGHTS, LBM
Total loaded*....................................................1,485.7
Propellant (including 0.6 lbm igniter propellant)..........
........................................................................1,392.0
Case assembly.....................................................37.9
Total inert*.............................................................93.7
Burnout*................................................................82.5
Propellant mass fraction*............................. 0.93*
Excluding remote S&A/ETA
TEMPERATURE LIMITS
Operation...................................................... 40º-90°F
V1101036 [507]
Storage....................................................... 40º-100°F
12,000 800
700
10,000
F
P
600 PROPELLANT DESIGNATION ........TP-H-3340
VACUUM THRUST, lbf
8,000
PRESSURE, PSIA
500
6,000 400 PRODUCTION STATUS........ FLIGHT-PROVEN

300
4,000
200
2,000
100
0 0
Dated 05 April 2016
96
STAR 31 AND 37 SERIES
97
STAR 31 TE-M-762
MOTOR DIMENSIONS
Motor length, in...................................................... 113

The STAR 31 Antares III is a third-stage rocket motor developed Burn time average thrust, lbf............................18,500
and qualified (1978 to 1979) for Vought Corporation’s Scout launch Maximum thrust, lbf..........................................21,500
vehicle. The design incorporates an 89%-solids HTPB propellant
NOZZLE
in a Kevlar® filament-wound case insulated with silica-filled EPDM
rubber. The STAR 31 first flew from the Western Test Range (WTR) Exit diameter, in..................................................28.67
in October 1979 to launch the MAGSAT satellite. Expansion ratio, initial...........................................58:1
WEIGHTS, LBM
Total loaded........................................................3,072
Propellant (including igniter propellant)..............2,835
Case assembly........................................................92
Nozzle assembly .................................................65.5
Total inert...............................................................237
Burnout..................................................................210
Propellant mass fraction...................... 0.92/0.93
(with/without external insulation)
TEMPERATURE LIMITS
Operation......................................................40°-90°F
Storage.......................................................20°-100°F

CASE MATERIAL
......................... KEVLAR-EPOXY COMPOSITE
PRODUCTION STATUS
.............................................. FLIGHT-PROVEN

OSR No. 16-S-1432; 98
Dated 05 April 2016
STAR 37FM TE-M-783
MOTOR DIMENSIONS
Motor length, in.....................................................66.5

The STAR 37FM rocket motor was developed and qualified (1984)
for use as an apogee kick motor on TRW FLTSATCOM, NASA NOZZLE
ACTS, GE/LM, and GPS Block IIR satellites and serves as the Initial throat diameter, in.......................................3.52
third stage on Boeing’s Delta II Med-Lite launch vehicle. The motor Exit diameter, in..................................................24.45
design features a titanium case, a 3-D carbon-carbon throat, and Expansion ratio, initial........................................48.2:1
a carbon-phenolic exit cone. The first flight of the STAR 37FM WEIGHTS, LBM
occurred in 1986. Total loaded*....................................................2,530.8
Propellant (including igniter propellant)...........2,350.1
Case assembly.....................................................71.1
Nozzle assembly/igniter assembly
Total inert............................................................180.1
Burnout*..............................................................162.5
Propellant mass fraction.............................. 0.93
*Excluding ETA lines and S&A
TEMPERATURE LIMITS
Operation.................................................... 20°-110°F
Storage....................................................... 40°-110°F
SPIN EXPERIENCE, RPM............................. 60

OSR No. 16-S-1432; 99
Dated 05 April 2016
STAR 37FMV TE-M-1139
MOTOR DIMENSIONS
Motor length, in.....................................................75.5

NOZZLE
The STAR 37FMV rocket motor was developed for use as an Initial throat diameter, in.......................................3.52
upper stage motor for missions requiring three-axis control. The Exit diameter, in..................................................29.46
motor design features a titanium case, a 3-D carbon-carbon throat, Expansion ratio, initial........................................70.0:1
Type......................................VECTORABLE + 4 DEG
a carbon-phenolic exit cone, and an electromechanically actuated
flexseal TVC nozzle. WEIGHTS, LBM
Total loaded*....................................................2,578.8
Case assembly.....................................................71.1
Nozzle assembly/igniter assembly
Total inert............................................................236.7
Burnout*..............................................................216.9
*Excluding ETA lines and S&A
16000 700 TEMPERATURE LIMITS

Operation......................................................40°-90°F
14000
P 600 Storage....................................................... 40°-110°F
12000
F
500
10000 )
)f ia
400 s
b p
(l
T
S 8000
(
E
R
PRODUCTION STATUS.......... DEVELOPMENT
U U
R S
H S
T 300 E
R
P
6000
200
4000
100
2000
0 0
0 10 20 30
TIME (sec)
40 50 60 70
OSR No. 16-S-1432; 100
Dated 05 April 2016
STAR 37XFP TE-M-714-16/-17
MOTOR DIMENSIONS
Motor length, in.....................................................59.2

Action time average chamber pressure, psia........523
Action time average thrust, lfb............................8,480
The STAR 37XFP TE-M-714-16 configuration was qualified as the Maximum thrust, lbf............................................9,550
orbit insertion motor for the Rockwell/Boeing Global Positioning NOZZLE

System Block II as well as for low earth orbit (LEO) insertion Initial throat diameter, in.......................................3.18
for RCA/GE/Lockheed Martin’s Television Infrared Observation Exit diameter, in..................................................23.51
Satellite (TIROS) and the Defense Meteorological Satellite Expansion ratio, initial/average.....................54.8/48.7
Type......................................... FIXED, CONTOURED
Program (DMSP), and as an apogee motor for RCA/GE/Lockheed
Martin series-4000 satellites. The TE-M-714-17 configuration was WEIGHTS, LBM (EXCLUDING REMOTE S&A/ETA)
qualified as the apogee motor for the RCA SATCOM KuBand Total loaded.....................................................2,107.1
satellite. The STAR 37XFP motor can be used as a replacement Propellant (including igniter propellant)...........1,948.2
Case assembly.....................................................58.1
for the STAR 37F motor, which has been discontinued. It features
Nozzle assembly (excluding igniter propellant)....70.0
a titanium case, 3-D carbon-carbon throat, carbon-phenolic exit
Internal insulation.................................................26.8
cone, and a head-end web grain design. This motor first flew from Liner........................................................................1.2
the Space Shuttle as an apogee kick motor (AKM) for SATCOM in Miscellaneous.........................................................2.8
1985 and has also been launched from Ariane and Delta launch Total inert (excluding igniter propellant)..............159.6
vehicles. Burnout...............................................................140.3
Propellant mass fraction.....................................0.925
S&A/ETA.................................................................4.2
TEMPERATURE LIMITS
Operation...................................................-32°-100°F
Storage........................................................-40°-90°F
CASE MATERIAL ..................6AI-4V TITANIUM

OSR No. 16-S-1432; 101
Dated 05 April 2016
STAR 37GV TE-M-1007-1
MOTOR DIMENSIONS
Motor length, in.....................................................66.2
MOTOR PERFORMANCE (70°F, vacuum)**

NOZZLE
Exit diameter, in....................................................23.4
Type..................................... VECTORABLE, ±4 DEG
WEIGHTS, LBM*
Total loaded........................................................2,391
Propellant ..........................................................2,148
Case assembly...................................................153.5
Nozzle assembly .................................................75.6
Total inert............................................................243.0
Burnout...............................................................228.6
The STAR 37GV composite case rocket motor was designed to
provide increased specific impulse and reduced inert mass to TEMPERATURE LIMITS
achieve a high mass fraction. It incorporates an electromechanical Operation.....................................................40°- 90°F
Storage.......................................................40°-100°F
flexseal thrust vector control (TVC) system that provides
±4-degree vectorability using electromechanical actuators. Mid- PROPELLANT DESIGNATION.........TP-H-3340
cylinder, head end, aft end, or custom skirts can be implemented CASE MATERIAL
easily to meet specific interface requirements. The STAR 37GV .....................GRAPHITE-EPOXY COMPOSITE
was demonstrated in a successful December 1998 static firing.
* Weights do not include TVA system hardware (actuators,
V0903006 [575]
16,000 14 00
brackets, controller, etc.) and reflect test motor configura-
14,000
F 12 00 tion
12,000
10 00 ** Motor performance reflects test motor configuration. By
10,000 optimizing the case design and increasing the operating
Pressure, psia
Thrust, lbf
P 80 0
pressure, we estimate that the flight weight motor will result
8,000
60 0
in a 15% performance increase
6,000
40 0
4,000
2,000 20 0

0
0 5 10 15 20 25 30 35 40 45 50 55
0
OSR No. 16-S-1432; 102
Time, sec Dated 05 April 2016
STAR 48 SERIES
103
STAR 48A TE-M-799-1
MOTOR DIMENSIONS
Motor length, in.....................................................80.0
MOTOR PERFORMANCE (75°F VACUUM)**

NOZZLE
SHORT NOZZLE
Exit diameter, in..................................................25.06
The STAR 48A motor was designed and tested in 1984 as an
increased payload capability version of the basic STAR 48 by
incorporating an 8-inch stretch of the motor case. The short nozzle WEIGHTS, LBM
version is designed to fit within the same 80-inch envelope as the Total loaded*....................................................5,673.7
long nozzle versions of the STAR 48 and 48B.
Case assembly...................................................153.6
The design uses a high-energy propellant and high-strength Nozzle assembly (excluding igniter propellant)....84.4
titanium case. The submerged nozzle uses a carbon-phenolic exit Total inert............................................................316.5
cone and a 3-D carbon-carbon throat. Burnout*..............................................................280.0
The case features forward and aft mounting flanges and Propellant mass fraction*............................. 0.94
multiple tabs for attaching external hardware that can be relocated *Excluding remote S&A/ETA
or modified for varying applications without requalification. TEMPERATURE LIMITS

Operation....................................................30°-100°F
Storage.......................................................30°-100°F
**Calculated thrust and impulse based on static test
data

OSR No. 16-S-1432; 104
Dated 05 April 2016
STAR 48A TE-M-799
MOTOR DIMENSIONS
Motor length, in.....................................................88.0

NOZZLE
LONG NOZZLE
The STAR 48A motor is designed as an increased payload Exit diameter, in....................................................29.5
capability version of the basic STAR 48 by incorporating an 8-inch Expansion ratio, initial........................................43.1:1
stretch of the motor case. The long nozzle version maximizes
performance by also incorporating an 8-inch longer exit cone, WEIGHTS, lbm
Total loaded*....................................................5,691.1
resulting in a longer overall envelope.
The design uses a high-energy propellant and high-strength Case assembly...................................................153.6
titanium case. The submerged nozzle uses a carbon-phenolic exit Nozzle assembly (excluding igniter propellant)..101.8
cone and a 3-D carbon-carbon throat. Total inert............................................................333.9
The case features forward and aft mounting flanges and Burnout*..............................................................294.3
multiple tabs for attaching external hardware that can be relocated
or modified for varying applications without requalification.
TEMPERATURE LIMITS
Operation....................................................30°-100°F
Storage.......................................................30°-100°F

OSR No. 16-S-1432; 105
Dated 05 April 2016
STAR 48B TE-M-711-17
MOTOR DIMENSIONS
Motor length, in.....................................................72.0

Maximum thrust, lbf.......................................... 17,110
NOZZLE
SHORT NOZZLE
Exit diameter, in..................................................25.06
The short nozzle STAR 48B was qualified in 1984 as a replacement
for the short nozzle STAR 48 used on the Space Shuttle Payload
Assist Module (PAM). The short nozzle configuration first flew from WEIGHTS, LBM
the Space Shuttle in June 1985 for ARABSAT. Total loaded*....................................................4,705.4
The design uses a high-energy propellant and high-strength
Case assembly...................................................128.5
titanium case. The submerged nozzle uses a carbon-phenolic exit
Nozzle assembly (excluding igniter propellant)....81.2
cone and a 3-D carbon-carbon throat. Total inert*...........................................................274.2
The case features forward and aft mounting flanges and Burnout*..............................................................245.4
multiple tabs for attaching external hardware that can be relocated Propellant mass fraction*............................. 0.94
or modified for varying applications without requalification. *Excluding remote S&A/ETA
TEMPERATURE LIMITS
Operation....................................................30°-100°F
Storage........................................................ 30°100°F

OSR No. 16-S-1432; 106
Dated 05 April 2016
STAR 48B TE-M-711-18
MOTOR DIMENSIONS
Motor length, in.....................................................80.0

NOZZLE
LONG NOZZLE Initial throat diameter, in.......................................3.98
The long nozzle STAR 48B was qualified in 1984 as a replacement Exit diameter, in....................................................29.5
for the long nozzle STAR 48 for the Delta II launch vehicle third Expansion ratio, initial........................................54.8:1
stage Payload Assist Module (PAM)-Delta. The long nozzle version
WEIGHTS, LBM
first flew in June 1985 from the Space Shuttle to place the Morelos
Total loaded.....................................................4,720.8
satellite in orbit. Propellant (including igniter propellant)...........4,431.2
The design uses a high-energy propellant and high-strength Case assembly...................................................128.5
titanium case. The submerged nozzle uses a carbon-phenolic exit Nozzle assembly (excluding igniter propellant)....96.6
cone and a 3-D carbon-carbon throat. Total inert*...........................................................289.6
Burnout*..............................................................257.8
The case features forward and aft mounting flanges and
multiple tabs for attaching external hardware that can be relocated
or modified for varying applications without requalification.
TEMPERATURE LIMITS
Operation....................................................30°-100°F
Storage.......................................................30°-100°F

OSR No. 16-S-1432; 107
Dated 05 April 2016
STAR 48BV TE-M-940-1
MOTOR DIMENSIONS
Motor length, in.....................................................81.7

NOZZLE
The STAR 48BV has been qualified (1993) as an upper stage
for EER System’s Conestoga Vehicle. The STAR 48V is derived Exit diameter, in..................................................29.43
from the highly successful STAR 48B (TE-M-711 series) rocket Expansion ratio, initial........................................54.8:1
motor. The STAR 48V provides the same range of total impulse Type..................................... VECTORABLE, ±4 DEG
as the STAR 48B with the long exit cone and includes an
electromechanically actuated flexseal nozzle thrust vector control WEIGHTS, LBM
Total loaded.....................................................4,772.0
system for use on a nonspinning spacecraft. Case attachment
Propellant .......................................................4,431.2
features can be modified or relocated for varying applications
Case assembly...................................................128.5
without requalification. Nozzle assembly .................................................. 116
Total inert............................................................339.8
Burnout...............................................................305.5
TEMPERATURE LIMITS
Operation....................................................30°-100°F
Storage.......................................................30°-100°F

OSR No. 16-S-1432; 108
Dated 05 April 2016
STAR 63 SERIES
109
STAR 63D TE-M-936
MOTOR DIMENSIONS
Motor length, in.....................................................70.0

Action time, sec.....................................................108
Action time average thrust, lbf..........................19,050
NOZZLE
The STAR 63, as part of the PAM DII upper stage, was flown from Exit diameter, in..................................................21.82
the Space Shuttle. The motor utilizes a head-end web and a carbon- Expansion ratio, initial........................................27.3:1
phenolic nozzle. The case material is a Kevlar-epoxy composite,
WEIGHTS, LBM
although future motors would be made using a graphite-epoxy
Total loaded.....................................................7,716.0
composite. Testing of STAR 63 series motors began in 1978 with
completion of the PAM DII motor qualification in 1985. The first Case assembly...................................................233.5
STAR 63D flight was from the Shuttle in November 1985 to place Nozzle assembly................................................134.0
a defense communication satellite in orbit. Total inert............................................................550.0
The motor derives its heritage from the Advanced Space Burnout...............................................................508.0
Propellant Demonstration (ASPD) and the Improved-Performance Propellant mass fraction.............................. 0.93
Space Motor II (IPSM) programs. On the ASPD program, a
TEMPERATURE LIMITS
delivered Isp of over 314 lbf-sec/lbm was demonstrated at
Operation....................................................30°-100°F
Arnold Engineering Development Center (AEDC). On the IPSM II Storage.......................................................30°-100°F
program, a dual-extending exit cone with a gas-deployed skirt was
demonstrated at AEDC. SPIN EXPERIENCE, RPM.................................85
In 1994, an 8-year-old STAR 63D motor was tested with a
flexseal nozzle. Designated the STAR 63DV, the motor successfully
demonstrated performance of the 5-degree TVC nozzle and CASE MATERIAL
electromechanical actuation system. ........................KEVLAR-EPOXY COMPOSITE*
* to be replaced with a graphite composite

OSR No. 16-S-1432; 110
Dated 05 April 2016
STAR 63F TE-M-963-2
MOTOR DIMENSIONS
Motor length, in...................................................106.7

Action time, sec.....................................................120
Action time average thrust, lbf..........................23,520
NOZZLE
Exit diameter, in....................................................39.4
The STAR 63F successfully completed qualification in 1990. It has
Expansion ratio, initial........................................78:4:1
been utilized as a stage for the Long March launch vehicle. The
motor is an extended-case version of the STAR 63D to increase WEIGHTS, LBM
Total loaded...................................................10,122.9
the propellant weight. With the addition of a larger nozzle, the
Propellant (including igniter propellent)...........9,401.6
STAR 63F delivers nearly a 300 lbf-sec/lbm specific impulse. Case assembly...................................................283.3
Like the STAR 63D, the motor case material was qualified with Nozzle assembly................................................ 211.4
Kevlar-epoxy composite and requires a change to graphite-epoxy Total inert............................................................721.3
composite. Burnout...............................................................643.3
TEMPERATURE LIMITS
Operation......................................................35°-95°F
Storage.........................................................35°-95°F
SPIN EXPERIENCE, RPM.................................85
CASE MATERIAL
........................KEVLAR-EPOXY COMPOSITE*
* to be replaced with a graphite composite

OSR No. 16-S-1432; 111
Dated 05 April 2016
112
STAR 75 SERIES
113
STAR 75 TE-M-775-1
MOTOR DIMENSIONS
Motor length, in................................................102.0**
MOTOR PERFORMANCE (75°F)

Burn time/action time, sec..............................105/107
Propellant specific impulse, lbf-sec/lbm............ 290.0*
Effective specific impulse, lbf-sec/lbm.............. 288.0*
Burn time average thrust, lbf.......................... 45,000*
Maximum thrust, lbf........................................ 55,000*
NOZZLE
Exit diameter, in.................................................28.5**
Expansion ratio, sea level, initial....................17.7:1**
The STAR 75 demonstration motor was made and tested
in December 1985 as a first step in the development and WEIGHTS, LBM
Total loaded......................................................17,783
qualification of perigee kick motors in the 9,000- to 17,500-lbm
Propellant (including 4.71 lbm igniter propellant)........
propellant range. The STAR 75 includes many design features .........................................................................16,542
and materials proven on previous Orbital ATK space motors: a Case assembly......................................................864
slotted, center-perforate propellant grain housed in a graphite- Nozzle assembly...................................................260
epoxy, filament-wound case and a submerged nozzle with a Total inert.........................................................1,126.4
carbon-phenolic exit cone. Propellant mass fraction.............................. 0.93
TEMPERATURE LIMITS
Operation....................................................30°-100°F
Storage.......................................................30°-100°F
CASE MATERIAL............... GRAPHITE-EPOXY

COMPOSITE
PRODUCTION STATUS....... DEMONSTRATED

*Predictions under vacuum with flight exit cone
**Demonstration motor

OSR No. 16-S-1432; 114
Dated 05 April 2016
STAR 92 SERIES
115
STAR 92
MOTOR DIMENSIONS
Motor length, in...................................................143.0

Burn time, sec.....................................................175.6
NOZZLE
Exit diameter, in....................................................42.4
Expansion ratio, average...................................39.0:1
WEIGHTS, LBM
Total loaded...................................................... 37,119
Propellant.........................................................34,879
Case ..................................................................1,418
The STAR 92 is a derivative of our successful STAR and Nozzle....................................................................634
CASTOR series of motors. It incorporates the motor heritage of Other......................................................................188
both systems and can be used in either a third-stage or an upper- Total inert ...........................................................2,240
Burnout...............................................................1,939
stage application. This design progressed to the point at which a
Mass fraction........................................................0.94
preliminary design review (PDR) was held.
TEMPERATURE LIMITS
Operation....................................................30 to 95°F
Storage.......................................................30 to 95°F
CASE MATERIAL............... GRAPHITE-EPOXY

COMPOSITE
PRODUCTION STATUS
.............DESIGN CONCEPT (THROUGH PDR)

OSR No. 16-S-1432; 116
Dated 05 April 2016
STAR STAGES
Orbital ATK offers a family of modular, high-performance upper stages based on our
STAR motor series. By employing common, flight-proven subsystems with available
STAR motor assemblies, Orbital ATK provides customers with optimized upper stages at
low development risk.The broad range of available STAR motor sizes and performance,
combined with our common avionics and mission-specific structures, allows exceptional
flexibility in configuring STAR-based stages to meet mission requirements.
The STAR stage architecture is compatible for use on a variety of launch vehicle applications
and can be provided in either a spin or three-axis stabilized configuration. The three-axis
stabilized stages include a gimbaled motor nozzle and electromechanical thrust vector
control while spin stabilized stages include a fixed motor nozzle and, as required, spin-up,
spin-down, and nutation control.
Orbital ATK uses avionics and pneumatic components, as well as flight software, that are
common with our launch vehicle programs to provide the STAR stage with the following
onboard capabilities:
• Guidance, navigation, and control (GN&C)
• Mission sequencing
• Attitude control
• Power
• Ordnance initiation
• Telemetry
• Post-separation collision and contamination maneuvers
• Flight termination system (if required)
The mechanical assemblies and interfaces of the STAR stage are designed and qualified to
meet the unique requirements of a particular mission. Orbital ATK provides the structures
that interface with the launch vehicle; house the electrical, ordnance, and attitude control
subsystems; and support the customer’s spacecraft. Depending on the application, the
motor can either be part of the primary load path or can be housed within an interstage
structure. Orbital ATK also provides the systems to separate the STAR stage from the
launch vehicle as well as to separate the STAR stage from the customer’s spacecraft, if
required.
117
Orbital ATK has successfully incorporated STAR motor-based stages onto existing Orbital
ATK launch platforms including Pegasus and Minotaur, and configured stages for mating
directly with the spacecraft as shown for the Lunar Prospector trans-luner injection stage.
Orbital ATK is currently developing a STAR stage

based on the STAR 48BV motor for a 2018 mission.
This mass efficient, three-axis stabilized stage and
its capability are shown below. The STAR 48BV
stage provides guidance, control, sequencing, and
electrical support throughout stage operation. In
this application, the STAR 48BV motor is part of the
primary load path to optimize mass efficiency. Orbital
ATK provides an adapter to interface the stage with
the launch vehicle as well as an avionics assembly
that houses the electrical and attitude control systems
and provides the interface to the spacecraft. Both the
launch vehicle adapter and the spacecraft structural
interface can be updated to support a wide array of
mechanical interface options.
With the flexibility inherent with our STAR motor STAR Stage 3700S
for NASA’s Lunar Prospector
performance and our common avionics approach,
Orbital ATK can deliver a STAR stage solution
optimized to meet specific mission requirements with low development risk and non-
recurring effort.
Example Stage Design Based on the STAR 48BV Motor
118
ELECTROMECHANICAL
THRUST VECTOR
ACTUATION SYSTEM
Orbital ATK has developed the first in a family of thrust vector actuation (TVA) systems
that is designed for low-cost modularity. The controller uses state-of-the-art electronics
packaged in a rugged and lightweight mechanical enclosure. Two-axis digital loop closure,
communication, and housekeeping functions are performed with less than half the
electronic piece part count found in similar TVA designs. An innovative, patented, digital
design enables this low-cost flexibility.
Derivative controller designs with different maximum output power capability of up to 33

Hp (without torque summing) can be produced from the same basic architecture. This is
also true for the actuator design, which can easily be scaled up or down to accommodate
almost any combination of output force and speed required.
119
TVECSTM Model TE-A-1154-1 Electromechanical Thrust Vector Actuation System
Product Description:
• Two-channel, linear output electromechanical actuation system
• Brushless DC motors
• Linear variable displacement transducer (LVDT) position feedback
• Resolver rate feedback
• Digital loop closure (position and rate)
• RS-422 communication
• Externally programmable for custom compensation
Options:
• Other stroke and null lengths available with minor actuator modifications (LVDT, ball screw,
housing lengths)
• Other communication protocols are available (RS-485, MIL-STD-1553, CAN, analog, etc.);
communication digital format is flexible
• Controller mounting provisions and cable lengths can be modified, as required
• Ability to reconfigure digital logic through main communication interface
• Enhanced reliability screening available (JANTXV, Class B, Class H, minimum, and space
level)
• Radiation tolerance
• Military temperature range
Product Characteristics
Main Power 80 VDC / 30 A (per channel)

Logic Power 28 VDC / 1A
Rated Speed 7.5 in/sec
Rated Load 1,600 lbf
Total Stroke 2.0 in
Null Length 8.394 in
Null Length Adjustment 0.2 in
Weight (not including battery) 21 lb
Design Capability
Operating Voltage, Main (max) 270 VDC
Current Limit, Main (max) 50 A
Maximum Output Force 3,500 lbf
Maximum Rated Speed 13 in/sec
Maximum Power Output 6 HP
120
ORION LAUNCH ABORT

SYSTEM (LAS) ATTITUDE
CONTROL MOTOR (ACM)
121
ORION LAS ACM TE-M-1174-1
MOTOR DIMENSIONS
Motor diameter, in........................................ 32.0
Motor length, in............................................ 62.8
MOTOR PERFORMANCE (60°F VACUUM)**

Burn time/action time, sec................... 29.4/32.3
Ignition rise time, sec................................. 0.120
Pressure, psia............... 2,180 boost/600 sustain
Maximum chamber pressure, psia............ 2,400
Total impulse, lbf-sec.........................99,000 min
Thrust, lbf......7,000 min boost/2,500 min sustain
NOZZLES
Eight, fully proportional valves with single fault
tolerant EM actuation and 100 msec response full
stroke
The attitude control motor was designed and tested between 2007 WEIGHTS, LBM
and 2010 to control pitch and yaw of the launch abort tower for the Total loaded*........................................... 1,629.1
Propellant (including igniter propellant)..... 608.2
Orion spacecraft during an abort maneuver. It is the first human-
Case assembly.......................................... 538.0
rated, single fault tolerant solid control system to be flight qualified
Valve assembly (each including actuator)... 23.3
and flew May 6, 2010 on the PA-1 flight.
Total inert................................................ 1,020.9
The design uses a medium-energy propellant and high-strength Burnout*.................................................. 1,019.0
D6AC steel case. The eight proportional valves utilize 4-D carbon- Propellant mass fraction*............................. 0.37
carbon, silicon carbide for the erosion-sensitive parts. *Excluding remote S&A/ETA
TEMPERATURE LIMITS
Operation............................................. 33°-99°F
Storage.............................................. 30°-100°F
CASE MATERIAL............................. D6AC steel

OSR No. 16-S-1432; 122
Dated 05 April 2016
ADVANCED SOLID AXIAL

STAGE (ASAS™) MOTORS
Orbital ATK’s ASAS family of high-
performance solid propellant motors is
adaptable to a wide variety of applications.
These designs incorporate proven design
concepts, materials technology, and
manufacturing techniques that provide
enhanced operational performance. The
technologies reflected in these motor
designs were identified and developed in
more than 425 tests performed as part of
technology programs conducted between
1985 and 2003 for the U. S. Air Force and
the Missile Defense Agency (MDA).
ASAS 21-in. Motor Firing (1998)
The ASAS family of motors employs, as
appropriate, design features including the following:
• High-strength, high-stiffness graphite-epoxy composite cases permitting increased operating
pressure to increase expansion ratio and enhance motor performance, particularly for
demanding interceptor applications
• Carbon-carbon throat materials that minimize throat erosion and related performance losses
• Erosion-resistant Kevlar-filled elastomeric insulation to provide thermal protection at minimum
weight
• High-performance conventional and advanced composite solid propellant formulations
providing required energy, temperature capability, and insensitive munitions (IM)
characteristics for each of the motor designs
• Electromechanically actuated, flexseal, or trapped ball thrust vector control (TVC) nozzle
technology
• Mission-specific component technology, including carbon-carbon exit cones, consumable
igniters, semiconductor bridge (SCB)-based ignition systems, integrated hybrid warm/
cold-gas attitude control systems, and isolation of multiple pulses with a barrier (rather than
bulkhead) insulation system
123
ASAS component and materials technology is mature, design scalability has been
demonstrated, related engineering design models have been validated, and common
components and materials are used in all of these booster configurations. These component
technologies have been successfully demonstrated in sea level and simulated altitude
tests and in successful flight tests.
By applying these proven technologies to new motor designs, Orbital ATK can offer:
1. Reductions in design, analysis, and development cost and schedule with streamlined
component- and motor-level test programs
2. Off-the-shelf component and materials technologies with proven scalability across a

range of booster configurations. This will reduce development risk and ensure that
performance will meet design specifications
3. Established tooling, manufacturing, and inspection techniques that provide

reproducible, high-quality products
The development philosophy for these motors has been to test a somewhat heavyweight
prototype or development unit to confirm design margins without risking failure. This first
firing is generally conducted at sea level. Scalability of ASAS design concepts and material
technology has been demonstrated in motors ranging from 4 to 32 inches in diameter and
will soon be demonstrated in a motor at 40-inches diameter.
124
Graphite-Epoxy Composite Case Winding

(21-in. booster)
Flexseal TVC Nozzle Assembly
Motor Static Firing at Simulated Altitude

(ASAS AKS-2 Qualification Motor)
SM-3 FTR-1A Missile Launch with ATK TSRM

(January 25, 2001)
125
ASASTM 13-30V
MOTOR DIMENSIONS
Motor length, in.....................................................39.3

Burn time, sec.......................................................14.3
NOZZLE
Exit diameter, in......................................................6.8
FIXED AND VECTORABLE UPPER STAGE MOTOR
The Advanced Solid Axial Stage (ASAS) 13-30V is a high- WEIGHTS, LBM
performance upper-stage motor derived from the Mk 136 Standard Total loaded*.......................................................250.9
Missile 3 (SM-3) Block IA/IB Third Stage Rocket Motor (TSRM). Propellant...........................................................195.8
Case ....................................................................40.2
The motor is 39.3 inches long and nominally designed as an upper-
Nozzle ....................................................................7.2
stage motor. The motor uses a pyrogen igniter for highly repeatable
Total inert..............................................................55.1
ignition performance. The motor incorporates a + 5-degree nozzle Burnout*................................................................53.5
powered by an Orbital ATK Thrust Vector Electronic Control
System (TVECSTM) thrust vector actuation (TVA) system using TEMPERATURE LIMITS
electromechanical (EM) actuators. Operation....................................................45°-120°F
Storage.......................................................30°-120°F
PROPELLANT DESIGNATION .........TP-H-3340A
CASE MATERIAL
............................. GRAPHITE-EPOXY COMPOSITE
PRODUCTION STATUS............FLIGHT-PROVEN
*Excludes ETA lines, safe and arm device, battery, and
controller

OSR No. 16-S-1432; 126
Dated 05 April 2016
ASAS 21-85V TE-M-1031-1
MOTOR DIMENSIONS
Motor length, in.....................................................95.5
MOTOR PERFORMANCE (75°F SEA LEVEL)

NOZZLE
Exit diameter, in.................................................... 11.6
TVC, deg............................................................. ±4.5
The ASAS 21-85V is a solid rocket motor with a graphite- WEIGHTS, LBM
composite case that was developed for sounding rockets and Total loaded........................................................1,656
high-performance guided booster applications. The initial 21-inch Propellant...........................................................1,444
Case assembly......................................................129
motor static test was conducted to demonstrate application and
Nozzle assembly.....................................................33
scaling of ASAS technology to vertical launch system-compatible
Total inert...............................................................212
large booster designs in April 1998. The design incorporated a
4.5-degree thrust vector control nozzle and a low-temperature
capable propellant. TEMPERATURE LIMITS
Operation...................................................-10°-130°F
Early test efforts led to a June 1999 test for the Air Force
Storage......................................................-20°-130°F
Research Laboratory that incorporated a fixed nozzle (blast tube)
arrangement to evaluate the use of low-cost materials and design PROPELLANT DESIGNATION .........TP-H-3514A
concepts. The ASAS II version of the motor also incorporated a
CASE MATERIAL
new propellant (TP-H-3516A) with 20% aluminum, 88.5% total ............................. GRAPHITE-EPOXY COMPOSITE
solids, and 1% plasticizer.
PRODUCTION STATUS..............DEVELOPMENT
V1098073F [413]
1800 18000
1600 16000
F
1400 14000
1200 12000
PRESSURE, psia
THRUST, lbf
1000 10000
P
800 8000
600 6000
400 4000
200 2000

0
0 5 10 15 20 25 30
0
OSR No. 16-S-1432; 127
TIME, sec Dated 05 April 2016
ASAS 21-120 TE-M-1059-1
MOTOR DIMENSIONS
Motor length, in...................................................138.0

The ASAS 21-120 is a solid rocket motor with a graphite-composite
NOZZLE
case that was developed in 2000 for vertical launch system (VLS), Initial throat diameter, in.......................................3.36
target, and sounding rocket applications. This is a fixed nozzle Exit diameter, in..................................................16.80
version of the ASAS 21-120V motor. Expansion ratio, initial...........................................25:1
WEIGHTS, LBM
Total loaded........................................................2,323
Propellant...........................................................2,036
Case assembly*.....................................................254
Nozzle assembly.....................................................32
Total inert...............................................................286
*Includes igniter without 1.08 lbm propellant
TEMPERATURE LIMITS
Operation....................................................40°-100°F
Storage.........................................................0°-100°F
CASE MATERIAL
V0301030A [482]
28000 2000
F
1800
24000
1600
20000 1400
PRESSURE, psia
1200
16000
THRUST, lbf
P 1000
12000
800
600
8000
400
4000
200
0 0
0 4 8 12 16 20 24 28 Approved for Public Release
TIME, sec OSR No. 16-S-1432; 128
Dated 05 April 2016
ASAS 21-120V TE-M-909-1
MOTOR DIMENSIONS
Motor length, in...................................................130.0
MOTOR PERFORMANCE (70°F SEA LEVEL)*

NOZZLE
Exit diameter, in....................................................14.0
TVC, deg..............................................................+5.0
The ASAS 21-120V solid rocket motor was designed, fabricated,
and tested in just four and one-half months after program start. It WEIGHTS, LBM
features a 5 -degree flexseal TVC nozzle with a carbon phenolic exit Total loaded........................................................2,236
Propellant (less igniter propellant)......................1,813
cone. This successful test led to receipt of the Strategic Defense
Case assembly*.....................................................363
Initiative Office Director's Award in recognition of outstanding Nozzle assembly.....................................................32
achievement. The ASAS 21-120V configuration is applicable to Total inert (including TVA)......................................423
vertical launch system (VLS), target, sounding rocket, and high- Propellant mass fraction.......................................0.81
performance guided booster applications. *Includes igniter without 1.08 lbm propellant
TEMPERATURE LIMITS
Operation....................................................40°-100°F
Storage.........................................................0°-100°F
2800 35000
PROPELLANT DESIGNATION ........... TP-H-3340
2800 30000 CASE MATERIAL

F ............................. GRAPHITE-EPOXY COMPOSITE
2800 25000 PRODUCTION STATUS..............DEVELOPMENT

*Development motor values. Flight design mass
PRESSURE, PSIA
fraction is 0.89 with total impulse improvement of

THRUST, LBf
2800 20000
approximately 15%.
P
2800 15000
2800 10000
2800 5000
2800 0 Approved for Public Release

0 4 8 12 16 20 24 28 32
OSR No. 16-S-1432; 129
TIME, SEC Dated 05 April 2016
ORIOLE
MOTOR DIMENSIONS
Motor length, in.................................................154.68
Oriole MOTOR PERFORMANCE (70°F VACUUM)

Burn time/action time, sec..........................30.0/28.85
Mk70 Terrier
The Oriole is a 22-inch-diameter, high-performance, low-cost rocket Burn time average chamber pressure, psia...........944
motor used as a first, second, or upper stage for sounding rockets, Maximum chamber pressure, psia.....................1,410
medium-fidelity target vehicles, and other trans-atmospheric Total impulse, lbf-sec......................................624,290
booster and sled test applications. The motor was developed in Propellant specific impulse, lbf-sec/lbm..............288.5
the late 1990s as a next-generation, high-performance sounding Burn time average thrust, lbf............................20,790
rocket motor and was first successfully static tested in 2000. Five Maximum thrust, lbf..........................................29,570
successful flight tests have been completed to date using the NOZZLE
Oriole as a second stage. The nozzle has been optimized for high- Initial throat diameter, in.......................................3.72
altitude applications and the graphite-epoxy case and modern Exit diameter, in..................................................19.82
high-performance propellant combine to provide a high-mass- Expansion ratio, initial........................................28.4:1
fraction and cost-effective design. TVC, deg ..............................................................N/A
Future Oriole variants are in concept development. These
WEIGHTS, LBM
include a version, for use as a booster in experimental scramjet
Total loaded........................................................2,588
or other similar applications, that has extra external insulation,
Propellant (less igniter propellant)......................2,152
allowing for extended flight times within the atmosphere. There is
Case assembly......................................................214
also a shorter burn time, first-stage booster specific version, which
Nozzle assembly...................................................145
would be an ideal replacement for Talos/Taurus class motors and
Total inert...............................................................436
would yield greater performance. The first stage incorporates a
low altitude optimized nozzle and has a burn time in the 12- to
15-second range. TEMPERATURE LIMITS
The Oriole motor also has the flexibility to accommodate a Operation......................................................0°-120°F
thrust vector control (TVC) system for high-fidelity target or orbital Storage......................................................-10°-125°F
mission applications. In addition, a subscale version, called the PROPELLANT DESIGNATION
Cardinal motor, is suitable for upper-stage applications with Oriole ............................QDL/SAA-144 ALUMINIZED HTPB
or other motors in the lower stage(s). The Cardinal motor would
be about half the size and weight of the full-scale Oriole motor and CASE MATERIAL
take advantage of many similar proven components and processes
to provide maturity and low-cost benefits. PRODUCTION STATUS.................IN PRODUCTION
30
MEOP =1620 psia

1.5
25
SEA-LEVEL THRUST, klbf
FORE-END PRESSURE, kpsia
20
F 1.0
15
P
10
0.5

0 0.0 OSR No. 16-S-1432; 130
0 5 10 15 20 25 30 35
TIME, sec Dated 05 April 2016
ASAS 28-185/185V TE-T-1032
MOTOR DIMENSIONS
Motor length, in......................................................207

NOZZLE
Exit diameter, in....................................................21.3
The ASAS 28-185 motor is a graphite composite case, fixed TVC, deg (design capability).................................. ±5
nozzle, solid rocket motor applicable to guided first-stage, sounding
WEIGHTS, LBM*
rocket, and target applications. With a thrust vector control nozzle, Total loaded........................................................6,901
the motor is designated ASAS 28-185V. The motor was tested on Propellant...........................................................6,172
September 30, 1998, and confirmed scaling of ASAS technology Case assembly......................................................608
from smaller motors to a 28.5-inch-diameter motor configuration Nozzle assembly...................................................121
Total inert...............................................................729
with extended burn time. Motor ignition was successfully achieved
Burnout..................................................................696
with a prototype electro-optical safe-and-arm (EOSA) device and
a semiconductor bridge (SCB) initiator. The motor incorporated a *weights without TVC
TVC nozzle simulator to evaluate thermal response for simulated
TEMPERATURE LIMITS
flexseal components, but the test nozzle was not vectorable by
Operation......................................................40°-90°F
design. Storage....................................................... 20°-110°F
PROPELLANT DESIGNATION ........... TP-H-3340

CASE MATERIAL

OSR No. 16-S-1432; 131
Dated 05 April 2016
ASAS 32-58V (RAVEN) TE-M-1106-1
MOTOR DIMENSIONS
Motor length, in.....................................................74.8

NOZZLE
Exit diameter, in....................................................16.9
Static tested on September 16, 2003, the ASAS 32-58V RApid Expansion ratio, initial...........................................28:1
Expansion cone half angle, exit, deg....................22.5
VEctoring Nozzle (RAVEN) design demonstrated an enhanced
Type............................................................Contoured
slew rate with a trapped ball nozzle using electromechanical TVC, deg............................................................. ± 12
actuation. The nozzle was tested on a 32-inch-diameter composite
WEIGHTS, LBM
case motor representative of a future missile defense interceptor
Total loaded........................................................2,618
second stage. The motor was ignited with an Orbital ATK Elkton Propellant ..........................................................2,296
electronic safe-and-arm (ESA) device and pyrotechnic igniter. Case assembly......................................................209
Motor design, analysis, fabrication, and successful static test Nozzle assembly (including actuators)..................104
efforts were completed in a five and one-half-month period. Igniter assembly (including ESA)...............................9
Total inert...............................................................322
Burnout..................................................................308
TEMPERATURE LIMITS
Operation......................................................45°-90°F
Storage......................................................-20°-140°F

35,000 1,800
1,600
CASE MATERIAL
30,000
Pressure
1,400
Thrust
25,000
1,200
Vacuum Thrust (lbf)
Pressure (psia)
20,000
1,000
800
15,000
600
10,000
400
5,000
200
0 0
Time (sec)
OSR No. 16-S-1432; 132
Dated 05 April 2016
LAUNCH STRUCTURES
133
ATLAS V STRUCTURES
CORE VEHICLE PRODUCTS
5M DIAMETER STRUCTURES
FABRICATED
WITH AUTOMATED
TECHNOLOGY
Featuring state-of-the art designs,
materials, and processes, the
Atlas V family of rockets offers
higher performance and greater Heat Shield
reliability than its predecessors.
The robustness of the Atlas V
system is enhanced by the use
of common system elements
assembled into a family of
vehicles that satisfy a wide range of mission requirements while
providing substantial performance margins.
Orbital ATK’s Role
• Three part configurations
1. Heat shield Interstage

2. Centaur interstage adapter (CISA)
3. Boattail
• Up to 5.4m in diameter (17.5 ft)
• Fabricated using automated fiber placement and advanced
hand layup techniques
• Manufactured at the Large Structures Center of Excellence
(COE) facility
Boattail
Customer: United Launch Alliance
Prime Contractor: United Launch Alliance

Orbital ATK Aerospace Structures Division has pioneered the use
of automated fiber placement for launch vehicle structures.

OSR No. 16-S-1432; 134
Dated 05 April 2016
DELTA IV STRUCTURES
COMMON BOOSTER PRODUCTS
CORE AND PAYLOAD
ACCOMMODATIONS
5M DIAMETER CORE
VEHICLE STRUCTURES
Delta IV is one of two
rockets currently in use
by the United States
Air Force’s Evolved Nose Cone
Expendable Launch Vehicle program. The Delta IV is designed to
reduce launch costs and provide assured access to space for U.S.
government, commercial, and civilian launch customers.
The Delta IV family consists of five launch vehicles based on a
common booster core first stage. The second stage is derived from
the Delta III, with expanded fuel and oxidizer tanks. GEM 60 strap-
ons can be added to provide additional launch capability.
Centerbody
• Family of 10 configurations
1. Centerbodies
2. Interstages
3. Thermal shields
4. Nose cones
5. Payload fairings
6. Payload adapters
7. X-Panels Thermal Shield

• Up to 5m in diameter (16 ft)
• Up to 19m in length (63 ft)
• Manufactured using advanced hand layup techniques,
machining, and inspection techniques at the Large
Structures COE facility
Customer: United Launch Alliance
Orbital ATK provides over 17 different part configurations for the

Delta IV family of launch vehicles.
OSR No. 16-S-1432; 135
Dated 05 April 2016
GEM
FAMILY OF COMPOSITE PRODUCTS
CASES
LIGHTWEIGHT CASES
SUPPORT MISSION AND COST
OBJECTIVES
The Delta family of launch vehicles
is configured with affordable,
high-performance graphite epoxy
motor (GEM) cases to provide
additional lift capability during first
stage ignition.
Designed to take advantage
of proven, off-the-shelf
technologies, the GEM system Orbital ATK’s Aerospace
provides increased performance and heavier lift capability than the Structures Division uses proven
hand layup techniques to produce
boosters of its predecessors. GEMs have demonstrated - through
GEM 60 nose cones
qualification and flight – that they are the most reliable, lowest cost
boosters available.
State-of-the-art automation, robotics, and process controls are
used to produce GEMs. Cases are filament wound at Orbital ATK’s
facility in Clearfield, Utah by computer-controlled winding machines
using high-strength graphite fiber and durable epoxy resin.
• Composite filament-wound cases
1. 40, 46 and 60 inches in diameter
2. Up to 42.5 ft. in length

GEM cases are produced using
3. Over 1150 cases delivered advanced filament winding
4. Production is in the 26th year techniques developed and refined
by Orbital ATK’s Aerospace
• Composite filament-wound igniter casings Structures Division for
• Composite aeroskirts and nose cones over 40 years
Customer: Orbital ATK

OSR No. 16-S-1432; 136
Dated 05 April 2016
ORION
FAMILY OF PRODUCTS
COMPOSITE
ROCKET
MOTOR CASES
OFF-THE-
SHELF
COMPOSITE
CASES FOR
COMMERCIAL
LAUNCH, Pegasus
MISSILE
DEFENSE, AND
SCRAM JET APPLICATIONS
The Orion family of composite structures is a versatile line of
structures supporting a range of mission platforms. Proven
manufacturing techniques, an outstanding performance record,
and affordability make Orion the rocket motor of choice.
Orbital ATK Aerospace Structures Division's Role
• Pegasus - First, second, and third stage rocket motor cases, Taurus
interstage, and payload fairing
• Taurus - First, second, and third stage rocket motor cases
• Minotaur - Third and fourth stage rocket motor cases
• Ground-based Midcourse Defense (GMD) Orbital Boost
Vehicle (OBV) - First, second, and third stage rocket motor
cases
• Proven filament winding and hand layup techniques
X-43C
• Demonstrated reliability and repeatability
Prime Contractors: Orbital ATK
GMD
OSR No. 16-S-1432; 137
Dated 05 April 2016
PEGASUS
PAYLOAD FAIRING
LIGHTWEIGHT,
AFFORDABLE
COMPOSITES
Initiated as a joint Air
Force and industry
venture in 1987, the
A proven hand layup
Pegasus launches A proven hand layup process
process developed by
small, mainly developed by Orbital ATK
ATK Composites
Composites is used tois used
fabricate
experimental Air Force payloads into low earth orbit (LEO). to fabricate the
the fairing components fairing
With over 37 successful missions and delivering more than 70 components
satellites to date, the Pegasus rocket has earned a reputation
as the world’s standard for affordable and reliable small launch
vehicles.
The composite payload fairing produced by Orbital ATK
separates approximately 110 seconds into flight, following second
stage ignition.
• Graphite/epoxy skins
• Aluminum honeycomb core
• 4.2-ft diameter; 14.2-ft length
• Hand layup construction
• Production is in 16th year
Prime Contractor: Orbital ATK
The Pegasus rocket is the first all-composite rocket to enter service.

OSR No. 16-S-1432; 138
Dated 05 April 2016
ORDNANCE PRODUCTS
Orbital ATK Elkton has produced a wide variety of ordnance products since the 1960s
including:
• Conventional electromechanical safe-and-arm (S&A) devices for STAR series space motor
initiation and launch vehicle/stage destruct functions
• Conical-shaped charge (CSC) assemblies for booster destruct applications on STAR,
CASTOR, Titan, Atlas, and Delta
• Semiconductor bridge (SCB)-based initiators for precise control of ordnance events for
military applications such as the universal water activated release system (UWARS) for the
U.S. Air Force
• Advanced electronics-based ordnance systems providing reductions in weight, enhanced
event control, and system health monitoring
Several of these products are illustrated below and provide an overall heritage of proven
reliability while providing flexibility to meet evolving customer needs.
139
Orbital ATK ordnance production facilities at Elkton include equipment for S&A assembly,
initiator manufacturing, igniter manufacture, pyrotechnic and explosives loading, and laser
welding. In addition to ordnance manufacture, Orbital ATK has facilities at Elkton to perform
nondestructive testing, including X ray, random vibration, shock and thermal environments,
functional testing, and associated live material and product storage.
V0298186 [390] V0298190 [390]
Lunar Prospector Command

Lunar Prospector Timer
Command andand
Timer S&A Integration
S&A Integration Conducted
Conducted byby Orbital ATK
ATK
Electromechanical S&As. The development and production heritage for electromechanical

S&A devices represents more than 40 years of product maturity as illustrated below. These
devices provide positive control of ordnance events in nonfragmenting and non-outgassing
designs that provide external status indication and a safety pin to inhibit operation when
desired. The current production Model 2134B is routinely used to initiate STAR series
space motors (next page) and for destruct on Atlas IIAS and Titan IVB. The Model 2134B
has supported more than 300 flights since 1989 with a 100% operational success rate. It
is Eastern-Western Range (EWR) 127-1 compliant and has flown successfully from ETR,
WTR, and Kourou and on vehicles such as Titan, Delta, Ariane, and Space Shuttle.
SA11906A [271]
S&A Development Heritage Supports Product

Reliability in Operation
140
Typical STAR Series Space Motor Ordnance

Train to Provide On-Command Ignition
Orbital ATK also supports S&A and ordnance system development having updated the
documentation package and manufacturing instructions for the Space Shuttle S&A device.
Orbital ATK also developed and qualified the Army Tactical Missile Systems (TACMS)
arm/fire device for motor ignition and the S&A device for Army TACMS warhead initiation
and has rebuilt or refurbished existing Minuteman III arm/disarm (A/D) switches for the
U. S. Air Force. For the Minuteman III A/D switch, six-sigma principals were employed
to design and implement a manufacturing plan that features manufacturing cells and
dedicated production stations. Trained technicians individually evaluate, rebuild, and then
retest each A/D switch. In addition, Orbital ATK has integrated complete ordnance systems,
which include Elkton-fabricated wiring harnesses for missile defense boosters such as the
Terrier lightweight exoatmospheric projectile (LEAP) Advanced Solid Axial Stage (ASAS)
and the SM-3 Mk 136 Third Stage Rocket Motor (TSRM). In the area of upper stages,
Orbital ATK conducted the design activity for the Lunar Prospector trans-lunar injection
stage. This upper stage used customer-supplied command timer/sequence to control all
ordnance functions including initiation of spin motors, separation systems, primary axial
propulsion, separation systems, and destruct functions (see below).
Laser Welding
Laser Equipment
Welding Equipment SCB Initiator
SCB Semi automated
Initiator Semi-
Manufacturing Line
Automated Line
141
Conical-Shaped Charge (CSC) Assemblies. CSCs produced at Orbital ATK provide a

concentrated destructive jet of energy for flight termination applications on a variety of
propulsion systems, including boosters used on Titan and Atlas as well as CASTOR and
STAR series motors. Orbital ATK conducts in-house testing for CSC lot acceptance and has
integrated destruct ordnance for stages including Lunar Prospector for Lockheed Martin
and NASA. CSCs produced at Orbital ATK are reviewed and approved by the Eastern and
Western Ranges for each application and meet the requirements of EWR 127-1. Photos
below show two past uses of the CSC.
V0298193 [390]
CSC Installed on Lunar Prospector STAR 48 Destruct Test Using Model

TLI Stage 2011 CSC
SCB Initiators. Since 1989, Orbital ATK has produced more than 60,000 SCB initiators for
application in automotive airbags, the mining industry, for parachute release, tank rounds,
and for motor and ordnance event initiation. The majority of this production has supported
the Universal Water Activated Release System (UWARS) program following qualification
of the device in 1994 (figure on following page). The flexibility and robustness of the basic
SCB initiator configuration enables Orbital ATK to tailor pin designs, output charges, and
design features for specific applications.
The SCB initiator provides advantages over other initiator technologies by providing low,
consistent initiation energy with fast and highly repeatable function times. These devices
enhance safety by readily passing no-fire requirements (>1 amp/1 watt/5 minutes), are
electrostatic discharge (ESD)-tolerant, can be tailored to meet MIL-STD-1385B HERO
requirements, and are qualified to MIL-STD-1512 requirements. This device produces a
Silicon Substrate
Bridge (volume of bridge)
Controls All: Fire/No-Fire Levels)
A A
0.050- in.
Square Aluminum Lands
Doped Polysilicon
Layer
Aluminum Lands
Doped Polysilicon
Layer
0.020 in. Silicon Substrate
Section A-A
SCB Chip and Initiator
142
Universal Water Activated Release System (UWARS)

8,500°F plasma at the bridge allowing initiation of insensitive materials. In addition, SCBs
are inherently mass producible at the chip and assembly level.
SCB initiators also provide excellent capability for health status monitoring and have
proven compatible with high-acceleration environments in gun-launched applications
(tank rounds), having survived forces in excess of 30,000 g. On-going SCB development
and production efforts conducted at Orbital ATK will further reduce unit costs and provide
compatible electronic initiation systems that can reduce overall ordnance system weight.
Advanced Electronics-Based Ordnance. Traditional launch vehicle and spacecraft

ordnance systems use dedicated, direct-wire systems. These systems employ bridgewire-
type squibs, shielded twisted pair cable harnesses dedicated to each squib, and an
electronic ordnance controller. Because the safety functions are performed in the ordnance
controller (remote from the point of initiation), the firing energy must be transmitted along
the entire length of the cable harness. The cabling must therefore be shielded from external
electromagnetic interference. Safety-critical initiation events are typically supported by
separate dedicated systems. This approach results in high system weight, larger cable
bundles, very limited health monitoring capabilities, and higher system power requirements.
As a result, Orbital ATK has developed ordnance products that can replace the conventional
S&A, explosive transfer assemblies (ETA), and through-bulkhead initiators (TBI) used for
this type of application. These advanced ordnance systems combine modern electronics
with SCB initiators to reduce weight and enhance reliability and safety for next-generation
ordnance applications versus conventional electromechanical systems. These products
are discussed below.
143
ESA. Among these products are the ESA, a device that contains
a single SCB initiator that produces an output approximately the
same as a NASA standard initiator (NSI). The ESA is designed
to thread directly into a motor igniter. It has a bulkhead to contain
motor pressure and a single electrical connector interface. The small
envelope and weight of this S&A permits direct installation into the
igniter and eliminates the need for ETAs and TBIs. The electronic
safety features of the ESA will be supplemented with a blocking
rotor mechanism driven by a small DC micromotor. The design will
mechanically and electrically isolate the electrical initiator from the
rest of the ignition train.
Orbital ATK performed initial environmental and operational testing of

prototype ESA units under the ASAS II contract (1999 to 2000). A prototype of the ESA was
also used to initiate an Orbital ATK technology demonstration rocket motor in November
2000 and Orbital ATK’s rapid vectoring nozzle (RAVEN) motor in 2003.
Addressable Bus Ordnance System. Under a 2001 and 2002 Advanced Ordnance
Development program, Orbital ATK designed, fabricated, and demonstrated a breadboard
addressable bus ordnance system based on ESA designs. The program also demonstrated
implementation of communication protocols allowing individual device control and the
ability to merge ordnance and telemetry system features on a single bus.
Addressable Bus Ordnance System Breadboard Prototype
Orbital ATK’s addressable bus solution mitigates or eliminates many of the negative
attributes associated with traditional ordnance systems. By substituting SCB-based squibs
as an enabling technology, a digital bus network will support multiple, individually addressed
devices (or nodes) that incorporate safety at the point of initiation and provide new, extensive
ordnance and system health monitoring and telemetry gathering capabilities. The Orbital
ATK-developed ESA device forms the basis of the initiator nodes in the proposed system.
Because firing energy is stored and switched at the individual system nodes, only low-
voltage power and digital commands are transmitted over the system cables. Significant
protection from external electromagnetic interference is therefore achieved without heavy
shielding. Individual cables are no longer necessary because all of the ordnance events
144
are controlled from a common bus that utilizes a digital communication protocol. As a
result, reductions in cabling mass and improvements in installation and checkout can be
realized.
Electro-Optical S&A (EOSA). Orbital ATK IGNITION CONTROL MODULE (ICM)

FIBER-OPTIC
has also demonstrated EOSA technology. CABLE
This approach combines laser light energy

and photovoltaic technology to control and
power electro-explosive devices (EED). An
advantage of this approach is that it uses fiber
optics and thereby isolates the EED from typical
electrical wires used to transfer energy and
commands. Orbital ATK worked with Sandia
SCB
National Laboratories to perform development INITIATOR
(REMOVABLE)
ELECTRO-OPTICAL
and demonstration efforts for all the critical 2 PLACES
INITIATOR (EOI) 2 PLACES
components including the ignition control EOSA

module (ICM), fiber-optic cabling, and electro-
optical initiators.
ARM PLUG ST® CONNECTOR, FC CONNECTOR,

CONNECTOR 2 PLACES 2 PLACES
VISUAL POWER AND

STATUS FI RE CI RCUI T COMMAND/CONTROL
LEDs CONNECTOR CONNECTOR
ESOA ICM
145
MODEL 2011 TE-0-958-1
DESTRUCT CONICAL CHARACTERISTICS
SHAPED CHARGE (CSC) U.N. classification code....................................... 1.1D
Orbital ATK’s Model 2011 Base charge..................Composition C-4: 500 grams
CSC is an upgraded version Booster charge................ Composition A-4: 17 grams
of the highly successful Model Cap material....................................... Aluminum alloy
2001 design developed in the Housing material................................. Aluminum alloy
1960s for use on the Delta Liner material...................................................Copper
launch vehicle. The Model Initiation input.................Flexible confined detonating
2011 has the same envelope, cord with Type III end tip
(144 mg HNS) (detachable)
mounting interfaces, and
Attachment interface.......................... Mounting flange
explosive weight as its
using a Marman clamp
predecessor, the Model 2001.
External finish.............................Clear anodic coating
The Model 2011 Penetration at 6-inch stand-off........12-inch mild steel
incorporates a 500-gram Temperature environmental extremes
composition C-4 main charge, which provides excellent safety, .......................................................... -65° to +160°F*
performance, and long-term storage characteristics for a variety Qualification vibration........... 47.7 grms for 3 min/axis
of flight termination applications. The Model 2011 is designed to Qualification shock........................... 6,000 g at 700 to
provide several improvements over prior CSC designs. These 3000 Hz, Q=10
include: 1) enhanced safety through the use of flexible confined Weight, gross......................................................2.8 lb
detonating cord input, 2) hermetic sealing of each unit, and 3) Applications...................... Solid motor destruct, liquid
incorporation of a liner manufactured to provide optimal target tank destruct, payload destruct
penetration and control of the jet angle. *High-temperature exposure up to 30 days
Orbital ATK has manufactured more than 1,000 CSCs for flight
termination. The Model 2011 was qualified for use on the Atlas IIAS
launch vehicle and was first flown in December 1993. Orbital ATK’s
CSCs have flown in many other applications including the Delta,
Japanese N, Titan/Centaur, and Atlas/Centaur launch vehicles.
They have been reviewed and approved by Eastern and Western
Range Safety for each application and meet the requirements of
EWR 127-1.
F C DC INP UT P OR T S
V 0592043C [042] 0.500 - 20 UNF -3B
ME T AL C -S E AL
S OC K E T HE AD C AP S C R E W ,
8 P LAC E S
B OOS T E R , C O MP A-4 C AP AS S E MB LY
(17.2 G R AMS )
MAIN C HAR G E , C OMP C 4

(500 G R AMS )
NAME P LAT E
5.24 IN.
HOUS ING
LINE R
E P OX Y
R E T AINING R ING
0.82 IN.
DIS C , Al,
0.015-IN.-T HIC K 4.23-IN. DIA
LAS E R W E LD
T O HOUS ING 5.32-IN. DIA
OSR No. 16-S-1432; 146
Dated 05 April 2016
MODEL 2134B TE-0-734
SAFE-AND-ARM (S&A)
CHARACTERISTICS·
DEVICE
Unit weight:............................ 3.4 lb (typical)
The Model 2134B was
Motor operating voltage:............................. 24-32 Vdc
originally qualified for the
Inrush:..........................1.0-3.0 amps for 50 ms max
McDonnell Douglas Delta
Running:..........................100-250 mA at 28 ±4 Vdc
II launch vehicle. Model Stalled rotor current:................................360 mA max
2134B has successfully Actuation time:................0.15 to 0.3 sec at 28 ±4 Vdc
flown on a number of launch Operating temperature:........................ –35° to 160°F
vehicles including Delta, Firing circuit pin-to-pin resistance:
Space Shuttle, Ariane, Titan, ................................. 0.87 to1.07 ohms (Version 1) or
Japanese N, and Long March. They have initiated upper-stage 0.90-1.10 (Version 2)
sequencing and booster destruct systems and ignited upper- Detonator “no-fire” current/power:
stage motors. Model 2134B improves upon the safe and reliable ........................................ 1 amp/1 watt for 5 minutes
Detonator “all-fire” current:..........................3.5 amps·
design of its predecessors by: 1) upgrading detonators to meet
Detonator (recommended)..............5.0 to 22.0 amps·
the requirements of MIL-STD-1576 and NHB1700.7A and 2) the
Firing time at 5.0 amps:......................... 3 ms (typical)
optional modification of the safety pin to comply with the safety
requirements of MIL-STD-1576 and EWR 127-1. Optional isolator mounts available for high shock/vibra-
tion environments
The Model 2134B is a nonfragmenting, non-outgassing,
electromechanical S&A initiation device that is remotely mounted PERFORMANCE FEATURES
and remotely actuated. Because of the nonfragmenting and non-  Nonfragmenting and non-outgassing
outgassing feature, the device can be located on spacecraft  Safe if inadvertently fired in the safe position
without damage to nearby equipment. The motive power for the  Remote electrical arming and safing
unit is furnished by a 28-volt reversible DC motor with an integral  The unit can be manually disarmed but cannot be
planetary gear speed reduction unit. The rotational power of the manually armed
DC motor is transmitted to the output shaft through spur gears and  Mechanical and electrical systems are inseparable
whether the device is operated electrically or
a friction clutch. manually
The explosive rotor assembly, visual indicator, and rotary  The firing circuit and explosive train are redundant
switches are located on the output shaft. These switches control  Firing circuits and control/monitor circuits are
the electrical circuitry, including motor control, remote indication, located in separate connectors
and firing signals. In the safe position, the explosive rotor assembly  Remote monitoring of safe or armed status is
integral within the circuitry
is out of phase with the explosive train. When the safety pin is
 A visual indicator window shows safe or armed
removed and arming current is applied, the output shaft rotates 90 status
degrees to align the rotor with the explosive train. If arming current  A safety pin prevents accidental arming of the unit
is applied with the safety pin installed, the motor operates through during transportation, handling, and checkout
the slip clutch to preclude any damage to the unit. The safety pin  The safety pin is nonremovable when arming
physically prevents the rotor from rotating while being mechanically power is applied
locked into place. The output area of the unit contains an adapter  In the safe position, the detonator lead wires are
shunted and the shunt is grounded through 15,000-
that provides interface of the explosive train with a receptor such
ohm resistors
as explosive transfer assemblies (ETA). The ETAs transfer the  Firing circuits have 25-ohm resistors to provide for
detonation output from the S&A device for purposes such as rocket ordnance system checkout in safe position
motor ignition. The unit’s redundant firing circuits and explosive
trains assure a highly reliable initiation.
The Model 2134B has a separate firing connector for each firing
circuit. A separate connector is also provided for the arm/disarm
and monitor circuits. OSR No. 16-S-1432; 147
Dated 05 April 2016
SCB INITIATOR TEM-I-902
Orbital ATK Elkton’s unique SAFETY/FEATURES/BENEFITS
squib design employs a  Contains no primary explosive material
patented semiconductor  Pyrotechnic material test data compatible to
bridge (SCB) to provide MIL-STD-1316 approved material
Qualified to MIL-STD-1512; human-rated
advantages over traditional 
 Passed electrostatic discharge: 25 kV, 500 pF,

hot-wire devices. Operation
through a 5,000-ohm resistor, over 100 pulses
of the SCB chip produces a  Passes 1-watt/1-amp, 5-minute no-fire require-
plasma output that enhances ment
safety by allowing the initiation  Passed –420°F performance testing
of insensitive materials (rather  Passed simulated 10-year aging
than primary explosives) in  Passed >50,000 g performance testing
the squib. It achieves highly  Passed 28-day temperature shock, humidity, and
altitude environments per MIL-I-23659
repeatable and fast function
 Radiated radio frequency sensitivity: MIL-STD-
times (as low as 50 msec). 1385B (HERO), design-dependent
The SCB initiator has been  Pressure shock: 15,000 psi
qualified to MIL-STD-1512 and serves as part of the human-rated  Monitor current: 100ma, 1,008 hours, -40° to
U.S. Air Force’s universal water activated release system (UWARS). 194°F, 42 cycles
The SCB takes only 10% of the energy required by a conventional  Low, consistent energy requirements (1 to 3 mJ)
bridgewire for initiation (requiring 1 to 3 millijoules versus 30 to  Highly repeatable, fast function time (as low as
50 µs);
35 millijoules for conventional bridgewire devices), but can meet
 Highly reliable (0.9992 at 95% confidence)
1-watt/1-amp for 5 minutes minimum no-fire requirements. The
 Requires 10% of the energy of a bridgewire
SCB interface configuration and all-fire and no-fire levels can be initiator
tailored for individual mission requirements. The device currently  Ability to customize interface configuration and
meets both Department of Defense and Department of Energy all-fire and no-fire levels
military requirements for electrostatic discharge.  Autoignition: 350°F for 6 hours; 257°F for 12
hours
The output of the squib and its mechanical interface can be
 Digital and optical addressable units available
tailored for specific applications. Our baseline initiator design
 Excellent heritage: over 40,000 units fabricated
serves as the core component for all our new devices, including and over 5,000 successfully tested
digitally and optically addressable units. Design modifications can  Handling shock: 6-foot drop, -65° and 215°F, 75
be made as necessary to accommodate new requirements or drops
optimize high-volume production needs.  Department of Energy-approved for use in
actuators of weapon systems
V 0592132K [042]
 Thermal shock: 200 cycles, -40° to 194°F, 1
hour per cycle; 120 cycles, -65° to 215°F, 1-hour
C HAR G E : T IT ANIUM S UB HY DR IDE dwell
0.170-IN. P OT AS S IUM P E R C HLOR AT E
DIA
"C "
0.30 IN. "B "

"A"

P IN C ONF IG UR A T ION - B E NT OR S T R A IG HT OSR No. 16-S-1432; 148
(A , B , C c us tomer defined) Dated 05 April 2016
ESA TEM-0-1068-1
The electronic safe-and-arm (ESA) UNIQUE DESIGN
Dimensions..................... 1-inch diameter, 3.2-inch long
is a low-power, stand-alone S&A
ESA assembly weight..................................~125 grams
device for ordnance initiation. Installed protrusion length................................. 2.2 inch
Designed as a drop-in replacement Material construction...................... 304L stainless steel
 Operates on typical 28 Vdc bus
for traditional electromechanical  Threaded interface
devices, it provides fail-safe, no  Harvard architecture microprocessor
 No primary explosives
single-point failure, arm and fire
FEATURES
interrupts, and physical blocking
 BIT capability
of pyrotechnic output in a smaller  Safe/arm monitor output (serial data)
and lighter weight package. Based  Initiator bridge verification

 LED visual status indicator
on Orbital ATK’s semiconductor
 Meets 1-amp/1-watt, 5-minute, no fire requirement
bridge (SCB) squib technology, the ESA provides advanced  Hermetic and maintains reliable pressure seal
(proofed to 20,000 psi)
electromagnetic interference immunity with safety at the point of
 Low-energy SCB initiator
initiation. By incorporating the SCB squib with a hermetic seal DEMONSTRATED
tested to >20,000 psi in the ESA, the traditional pyrotechnic transfer  Tested in STAR motor ignition systems
train components can be eliminated to allow for reduced hardware  Tested in 21- and 24-inch-diameter tactical motor
ignition systems (ASAS boosters)
and lot acceptance test costs as well as reducing the burden of  Tested in test motor
tracking items with limited shelf life. Added benefits of the ESA  Baseline for new design STAR motor ignition
system
not available in electromechanical S&As are automatic built-in
SAFETY
test (BIT) capability plus the availability of serial status telemetry  Independent arm and fire inhibits
including safe/arm status and bridge resistance verification.  Arm and fire sequence requirements
 Dual safing methods; quick safe feature and dual-
bleed resistors for fail-safe discharge
 High- and low-side switch protection to isolate SCB
from stray energy
 Range safety reviews successfully completed
Eastern/Western Range Review................ Spring 2000
Range Commanders Council Review......... Spring 2000
U.S. Army Safety Review Board......................Fall 1999
SYSTEM PERFORMANCE
Arm signal voltage output........................... 22 – 36 Vdc
Peak power........................................ 7 W for 150 msec
Average power..................................................... 1.4 W
Transient current........................<250 mA for 150 msec
Steady-state current.......................................... ∼ 50 mA
Arm time.......................................................<100 msec
Fire signal voltage input.............................. 18 – 36 Vdc
Steady-state and transient current.................... <10 mA
Fire output time...............................................<10 msec
Quick safe.........................................................<1 msec
Bleed safe............................................................<7 sec
SCB firing time................................................ <50 µsec
 Operates over long distances (several hundred
feet)
 Extensive diagnostic and system status monitoring
 Capable of autonomous timing of events

OSR No. 16-S-1432; 149
Dated 05 April 2016
EOSA TE-O-1054-1
SAFETY FEATURES
 Three independent and unique inhibits
 Dedicated connector for FIRE commands
 Dual safing methods:
 SAFE command for rapid capacitor discharge
 Dual bleed resistors for capacitor discharge for
fail-to-safe loss of signal
 Visual LED status indicators for POWER, ARM,
and SAFE
 Isolation from stray electrical and electromagnetic
interference energy at the point of initiation
 Coded optical commands for immunity to stray
optical energy
 Arming plug removal to interrupt all electrical
Orbital ATK is developing an electro-optical safe-and-arm (EOSA) power to the control module
device that combines laser light energy and photovoltaic technology  Does not utilize direct initiation of ordnance by
to safely and reliably initiate electro-explosive devices. laser light
The EOSA consists of an ignition control module (ICM), dual PHYSICAL CHARACTERISTICS
fiber-optic transmission cables (FOTC), and electro-optical initiators EOSA assembly weight....................................1.50 lb
(EOI). This system provides complete isolation of the electrical ICM.......... 1.63-in. high x 3.50-in. wide x 4.44-in. long
EOI...................................1.20-in. dia. X 2.34-in. long
initiator from sources of energy that could cause inadvertent
Fiber size........................100-micron silicon core fiber
initiation. All power, command, and data signals are transmitted
optically between the ICM and the EOI by laser diodes via fiber SYSTEM PERFORMANCE
optic cables. The optical signals are then converted to electrical Operating voltage.............................................28 Vdc
signals by photovoltaic converters for decoding and action. Peak power (per channel)...................... 5W for 1 sec
Average power (per channel)................................ 3W
This relieves the system from transmission loss effects over
Arming/safing time..............................1 sec maximum
long cable lengths that are detrimental to direct laser ordnance
Firing time.................................................... 100 msec
initiation systems and from the shielding and noise penalties
 Dual channels for complete redundancy
associated with electrical transmissions.  Automatic BIT with extensive diagnostic and
System input/output, self-diagnostic functions, arming plug, and system health monitoring
visual safe/arm indicators are contained in the ICM. Safe-and-arm  Ability to operate over hundreds of feet of cable
functions and the initiator squib are contained in the EOI and are  Autonomous timing and sequencing of events
activated by coded optical signals from the ICM. System arming
causes the EOI to charge a capacitor locally storing the firing
energy at the point of initiation. The FIRE command from the ICM
causes the EOI to discharge the capacitor to the initiator squib
causing it to fire. Either the SAFE command or the loss of signal
from the ICM will cause the EOI to rapidly discharge the capacitor
through bleed resistors rendering the system SAFE.
A built-in-test (BIT) capability provides a real-time system
check and feedback of the safe/arm status to the user both visually
and through vehicle telemetry. The design uses Sandia National
Laboratories’ patented electro-optical initiation technology and
Orbital ATK’s patented MIL-STD-1512 qualified semiconductor Approved for Public Release
bridge (SCB) initiator. OSR No. 16-S-1432; 150
Dated 05 April 2016

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Orbital ATK, Inc.

Orbital ATK, Inc.

SOLID ROCKET MOTOR UPGRADE (SRMU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

STAR 31 and 37 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

CSC Conical shaped charge — An ordnance product typically used as part of

CTPB Carboxyl-terminated polybutadiene — A type of polymer used as a

EOSA Electro-optical safe and arm — A class of safe-and-arm device based on

EPDM Ethylene propylene diene monomer — A class of elastomeric rubber

ETR Eastern Test Range

GBI Ground-based interceptor

shelf technologies, the GEM system provides increased performance and

GMD Ground-based Midcourse Defense

GPS Global positioning system — A satellite constellation providing precise

GSE Ground support equipment — Equipment used to support motor integration

HTPB Hydroxyl terminated polybutadiene — A type of polymer used as a

IMP Interplanetary monitoring platform

IRBM Immediate-range ballistic missile

JPL Jet Propulsion Laboratory, Pasadena, CA

LCS Large class stage – A high-performance, high-reliability booster being

MDA Missile Defense Agency

NSI NASA standard initiator

PBAN Polybutadiene acrylic acid acrylonitrile polymer — A binder formulation

RAD Rocket-assisted deceleration — Designation for motors used to decelerate

RAVEN RApid VEctoring Nozzle

RCS Reaction control system

S&A Safe and arm — Used to designate an electronic or electromechanical

SLS Space Launch System

SRM Solid rocket motor

SSB Solid strap-on booster

STS Space Transportation System — The Space Shuttle

TBI Through bulkhead initiator — Part of a space motor ignition train

TLI Trans-Lunar Injection — Designation for a motor system used to inject a

TCR Orbital ATK line of resins and pre-impregnated composite materials

TIRS Transverse impulse rocket system — Designation for motors used to

TVC Thrust vector control — Refers to a type of movable nozzle

WTR Western Test Range

RSRM Boosters GEM and STAR Propulsion CASTOR and Orion

STAR 48 Motor and Magellan Lunar Prospector LCS I Static Test

Copyright © 2016 by Orbital ATK, Inc. All rights reserved.

Sometimes existing designs must be modified, stretched, offloaded, or scaled up to achieve

Rapid Vectoring Nozzle (RAVEN) ASAS 21-120 Motor Test

In addition to hardware, Orbital ATK routinely provides a variety of support services,

Shipping Container Lunar Prospector Size

Products Contact No. Contact E-mail Address

LARGE MOTOR SUMMARY

Orbital ATK Motor Comparision

* In development, subject to refinement

ORION MOTOR SERIES

AFFORDABLE, LOW-RISK FLEXIBLE CAPABILITIES

Flight-Proven Orion Motor Configurations

50ST 50T 38 Taurus

50S XL 50 XLT 38 Taurus XL/

50S XLG 50 XL 38 GMD GBI

50S XLG* 50 XLT IRBM target

* with lengthened nozzle

Motor Identification Key

 SRM diameter (in)

 XL or Std motor length

MOTOR PERFORMANCE (60°F NOMINAL,

** Pegasus standard first stage

Approved for Public Release

MOTOR PERFORMANCE (60°F NOMINAL,

TVA .................................................. OPTIONAL